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Abstract:

A flexible material that comprises one or more types of polymers and may
be used for drawing surface-adhesive rules having a pre-defined
cross-section profile. Wherein the flexible material has attribute to
reserve a shape of a profile of an orifice through which it is deposited
from.

Claims:

1. A surface-adhesive rule flexible material, comprising: a flexible
material comprising one or more types of polymers; wherein the flexible
material has attributes to reserve a shape of a profile of an orifice
through which it is deposited from; and wherein the flexible material is
used for drawing surface-adhesive rules having a pre-defined
cross-section profile.

2. The surface-adhesive rule flexible material of claim 1, wherein the
attribute to reserve a shape of a profile comprise thixotropic attribute.

3. The surface-adhesive rule flexible material of claim 1, wherein the
attribute to reserve a shape of a profile comprise pseudo plastic
attribute.

4. The surface-adhesive rule flexible material of claim 1, wherein the
attribute to reserve a shape of a profile comprise is within 10 percent
of the profile of the orifice through which it is deposited.

5. The surface-adhesive rule flexible material of claim 1, further
comprise one or more additives.

6. The surface-adhesive rule flexible material of claim 5, wherein the
one or more additives is above 10 percent silica.

7. The surface-adhesive rule flexible material of claim 1, wherein the
flexible material comprise bonding capabilities to a surface of a die's
body.

8. The surface-adhesive rule flexible material of claim 7, wherein the
bonding capabilities are by adhesion.

9. The surface-adhesive rule flexible material of claim 8, wherein the
adhesion is by an intermediate substance between a surface of a die's
body and the surface-adhesive rule.

10. The surface-adhesive rule flexible material of claim 8, wherein the
adhesion is by an adhesion attribute of the flexible material.

35. The surface-adhesive rule flexible material of claim 1, is delivered
in a cartridge.

36. The surface-adhesive rule flexible material of claim 1, wherein the
one or more types of polymer is polycarbonate.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This is a utility patent application being filed in the United
States as a non-provisional application for patent under Title 35 U.S.C.
§100 et seq. and 37 C.F.R. §1.53(b) and, claiming the benefit
of the prior filing date under Title 35, U.S.C. §119(e) of the
United States provisional application for patent that was filed on May
17, 2010 and assigned Ser. No. 61/345,180, which application is
incorporated herein by reference in its entirety. This application is
related to and filed concurrently with: U.S. application Ser. No. ______
bearing the title of METHOD AND SYSTEM FOR SURFACE ADHESIVE RULE
TECHNOLOGY, filed on May 16, 2011 under the attorney docket number
08025.1030; U.S. application Ser. No. ______ bearing the title of METHOD
AND SYSTEM FOR CREATING CO-LAYER SURFACE ADHESIVE RULE, filed on May 16,
2011 under the attorney docket number 08025.1040; and U.S. application
Ser. No. ______ bearing the title of METHOD AND SYSTEM FOR CREATING
SURFACE ADHESIVE RULE COUNTER DIE, filed on May 16, 2011 under the
attorney docket number 08025.1050.

TECHNICAL FIELD

[0002] The present disclosure generally relates to die-cutting/creasing
industry, and more particularly the disclosure relates to a system and
method of manufacturing die-cutting/creasing and preparing pre-treated
cardboards/papers.

BACKGROUND ART

[0003] The rapid evolution of trade around the world (globalization)
creates a significant demand for packaging in order to
transfer/distribute goods to different remote areas. The transport of
goods may be done by: ship, airplanes, trucks, and so on. The transport
of goods may be performed by: the manufacturer; different suppliers;
individual persons; etc. Further, a significant demand for different
brochures, flyers, etc., also takes part in trade. The different
brochures/flyers may have pre-folds and/or embossing, for example.
Embossing such as, but not limited to Braille writing.

[0004] Packaging takes a major role in the marketing today. The package in
which the goods are packed and presented, in a store for example, may
determine if the goods will be appealing to a potential buyer in the
store or not. Thus the packaging appearance can have a direct effect on
the sales of merchandise. The brochures, flyers, and so on may also
contribute to the sales/awareness to a product/service etc.

[0005] Henceforth, throughout the description, drawings and claims of the
present disclosure, the terms package, paperboard box, parcel, box,
carton box, cardboard box, brochure, flyers, etc. may be used
interchangeably. The present disclosure may use the term package as a
representative term for the above group.

[0006] A known preliminary requirement, in order to construct a package,
is preparing or purchasing a pre-treated cardboard and/or paper based
material. Paper based material may be of different types. Exemplary types
may be: waxed paper, cartridge paper, art paper, etc. Henceforth,
throughout the description, drawings and claims of the present
disclosure, the terms cardboard, card-stock, display board, corrugated
fiberboard, paperboards of different paper based material, folding
boxboard, carton, blanks, and so on, may be used interchangeably. The
present disclosure may use the term cardboard as a representative term
for the above group.

[0007] The pre-treatment of a cardboard may include the following acts:
creating folding lines along the cardboard to ease and provide accurate
folding of the cardboard; piercing the cardboard in different areas;
creating embossment in different areas of the cardboard; cutting the raw
cardboard into predefined shapes; and so on. Henceforth, the description,
drawings and claims of the present disclosure the terms pre-folded
cardboard, and pre-treated cardboard may be used interchangeably. The
present disclosure may use the term pre-treated cardboard as a
representative term for the above group.

[0008] Some common techniques for preparing a pre-treated cardboard
include the acts of placing the cardboard between dies. Known dies are: a
steel-rule die and a counter-die. The steel-rule die may include a
variety of different types of dies. Exemplary types of dies can be: a
cutting-die; a creasing-die; an embossing-die; a scoring-die; a
combination of the different types of dies; and so on. The steel-rule die
body is usually a hard-wood-based material. Exemplary hard-wood-based
material may be: plywood, maple wood, etc. Other exemplary material may
be: plastic, metal, fabric, etc. The body material is required to have a
high-dimension stability and a high-grade and be without voids or other
imperfections.

[0009] Jammed deeply and firmly into a plurality of pre-made slots inside
the steel-rule die's body is a plurality of steel-rules. The pre-made
slots hold the steel-rules in place during the production of the
steel-rule die. Further, the pre-made slots support the steel-rule during
the operation of the cutting/creasing/embossing of numerous cardboards.
The steel-rules are usually cut and bent blades made of hardened steel,
for example. Usually, around the steel-rules, a plurality of ejection
(rebound) rubbers need to be placed and glued. Without the ejection
rubber the cardboard may tend to get stuck amongst the steel rules.

[0010] The counter-die comprises a body. The body is usually a
hard-wood-based material. Other exemplary material may be: plastic,
metal, fabric, etc. Commonly, a plurality of trenches is grooved in the
counter-die. The trenches location and structure is required to fit
precisely to the location and structure of the steel-rules of the
steel-rule die.

[0011] Known common techniques of manufacturing steel-rule dies include
the acts of: preparing slots in the die's body (the wood for example) for
the steel-rules. This is commonly done by a station using laser or
special bandsaw, for example. Next a specialist cuts and bends the steel
rule and positions them into the slots in the body. The positioning
requires hammering the steel-rules deeply into the slots. Adjustments of
the height of the steel-rule protruding from the body of the die are
usually required as well. A specialist will then need to glue a plurality
of ejection rubbers around the steel-rules.

[0012] Known common techniques of manufacturing the counter-dies include
several actions. For example, during the production of the counter-die
one or more inexpensive material (inserts) may be associated to the
counter-die's body. The inserts may be associated to the body by screws,
nails, re-positional adhesive, etc. The inserts may be made of
phenolic-resin, paper, fabric, for example. The inserts may comprise
trenches in it. The inserts are positioned so that their grooves/trenches
are aligned/centered with the corresponding steel-rules of the steel-rule
die. The alignment/centering of the inserts is usually performed by a
specialist.

[0013] A trial cutting/creasing/embossing operation can then be made
between the steel-rule die and the counter-die, together with a sheet of
paper-based material between them, for example. If the
alignment/centering is not satisfactory, the specialist detaches the
inserts from the counter die and re-positions them. If the
alignment/centering is satisfactory, the specialist can groove trenches
in the counter die's body precisely where the trenches of the insets were
and detach the inserts from the body. In alternate embodiments, the
inserts with the trenches may be left on the counter die's body and act
as the trenches.

SUMMARY OF DISCLOSURE

[0014] In the common steel-rule die and counter-die industry, the rules
material (steel, for example) enables the creasing/cutting/embossing of
the cardboards while having a good sustainability and durability to the
numerous slamming and pressure of the counter die on the steel-rule die
during the cut/crease/emboss operation. The common rules (usually steel
rules) are hammered deep inside the die's body (usually hard-wood-based
material) in order to enable and assure that they will be fixed in place
even at the harsh operation which can be around a few ton press force
(100 ton press for example) in a plurality of directions on the common
rules. Commonly the steel-rules are inserted deep inside the die's body
(18 mm, for example). The die's body thus is usually very dense heavy and
thick and the grooves in the body, for the common rules, are usually
deep.

[0015] The common steel-rule die and counter-die industry requires a
complex operation and collaboration between different entities. Entities
may be different companies, for example. For example, if a client
requests a certain package to be made for him, the following scenario
usually may take place in the common industry:

[0016] (a) A first entity may be a company that prepares a sample of a
prototype of the requested package.

[0017] (b) This prototype needs to be transport to the client for
approval, and, if the client does not approve. This step needs to be
repeated until the client is satisfied.

[0018] (c) Next an order for a common steel-rule die and counter-die needs
to be made. This step may be performed by a different entity (a second
entity). The second entity needs to acquire die body (wood for example),
steel-blades, and insert-material. People skilled in the art of
die-making will need to: groove the die's body; cut and bend the
steel-rules; hammer the steel-rules in place; glue the ejecting rubbers;
attach the insert to the counter-die body; center and groove the
counter-die's trenches in precise required location; etc.

[0019] (d) Next, the common steel-rule die and counter-die will need to be
transferred (by truck, ship, airplane, etc.) to a third entity. The third
entity will need to: install the received common steel-rule die and
counter-die to a press/die machine; set-up the machine and fine tune it;
insert cardboards; and gather the pre-treated cardboards.

[0020] (e) The common steel-rule die and counter-die will then need to be
stored for future use. The storage is usually a big warehouse since the
common steel-rule die and counter-die are very big and heavy.

[0021] (f) Lastly the pre-treated cardboards need to be sent to the client
(by truck, ship, airplane, etc.).

[0022] Thus, those skilled in the art will appreciate that the common
steel-rule die and counter-die industry requires different craftsmen,
long time leads for production, relies heavily on transportation,
consumes tons of wood and/or tons of steel, demands huge storage areas,
generates environmental pollution, and involves a complex cooperation
between different companies, etc.

[0023] The above-described deficiencies in common die-cut/crease/emboss
industries do not intend to limit the scope of the inventive concepts in
any manner. They are merely presented for illustrating an existing
situation.

[0024] Among other things, the present disclosure provides a novel system,
apparatus and method for a novel surface-adhesive-rule technology (SART).
In the novel surface-adhesive-rule technology (SART), the rules may be
adhered to the surface of the body of the die. Thus, there is no need to
groove the body, place precisely and hammer the rules inside trenches of
the die's body. In exemplary embodiments, the surface may be smooth;
however, it will be appreciated that in alternate embodiments, the
surface may not be smooth. For example the surface may be: scraped, laser
burned, etc. The rules of the surface-adhesive-rule technology (SART) may
include a variety of different types of rules. Exemplary types may
include: cutting rules; creasing rules; embossing rules; etc. Henceforth,
throughout the description, drawings and claims of the present
disclosure, the terms cutting rules, creasing rules, embossing rules,
etc. may be used interchangeably. The present disclosure may use the term
rule as a representative term for the above group.

[0025] The novel surface-adhesive-rule technology (SART) enables the
manufacture of a complete surface-adhesive-rule die with the creation of
its surface-adhesive rules (SAR) by one machine. Thus, advantageously,
utilizing the SART alleviates the requirement for complex operation
between different companies. Furthermore, another advantage of the
surface-adhesive-rule technology (SART) is that it may be fully automatic
and controlled by a computer, for example. Thus, no skilled craftsmen
(specialists) are required in the manufacturing of a die. In addition,
the surface-adhesive-rule technology (SART) alleviates the need for
warehouse space because the layout and all information related to the
surface-adhesive-rule die may be stored on a computer or other storing
medium such as CDROM, flash disc, etc. Thus the novel
surface-adhesive-rule technology (SART) advantageously provides a
low-cost, easy to use, friendly to the environment, and a shortened
lead-time for production of a full surface-adhesive-rule die and counter
die.

[0026] In exemplary embodiments, including some of the embodiments
described in the present disclosure, the surface-adhesive rules (SAR) of
the surface-adhesive-rule technology (SART) may be made of
flexible-material. The flexible material may be liquid or gel like
material. The flexible-material may include one or more different types
of polymers or even different combination of differing types of polymers.
Exemplary polymers that may be used may include: polyester, polyamide,
polycarbonate, polyurethane, acrylic, polypropylene, polyethylene, etc.
Furthermore, the flexible-material may include one or more additives.
These additives may include, but not limited to: silica, ceramics, metal,
various fibers, different fillers, etc.

[0027] In exemplary embodiments, the flexible material of the
surface-adhesive rules (SAR) may comprise several layers (co-layer). Each
layer may be made of different materials. Each layer may also have a
different: shape; cross-section; width; comprise different polymer types
and/or additives; etc. Each layer may have a different required
attribute. For example the lower layer may be required to have better
adhesive attributes, the highest layer may be required to have more
elastic attributes, and so on.

[0028] The disclosed novel surface-adhesive rules (SAR) may have a strong
enough sustainability, firmness, inside-cohesion, robustness, and/or
lifespan to withstand the pressure and harsh operation of high pressure
press force (1-10 ton, for example) in one or more directions on the
surface-adhesive rules during the cutting/creasing/embossing operation of
the cardboards.

[0029] The flexible material (the liquid or gel like material) of the SAR
may have additional attributes (attributes). Exemplary attributes may
include the ability of the flexible material to reserve the required
surface-adhesive rule (SAR) profile while drawing the SAR on the
surface-adhesive-rule die's body (SARD) surface. Wherein the reserve the
required surface-adhesive rule (SAR) profile is within plus minus a few
percentage (between 5-15 percent) from the profile of an orifice of a
nozzle through which the flexible material is deposited (drawn) as a SAR
for a period of few seconds to few hours, for example. Other exemplary
embodiments the reserve the required surface-adhesive rule (SAR) profile
may be plus minus a 10-30 percentage from the shape of the profile for a
few minutes to tens of minutes, for example.

[0030] The ability to reserve the required surface-adhesive rule (SAR)
profile while drawing the SAR may be achieved by attributes of the
flexible material. Exemplary attributes of the flexible material such as,
but not limited to: thixotropic, pseudo plastic, hardness, high
viscosity, etc. The attributes required to enable reserving the required
surface-adhesive rule (SAR) profile may be achieved by the composition of
ingredients. Exemplary composition of ingredients may comprise: 7-50
percent additives such as but not limited to: silica, filers, etc. In
other exemplary embodiments the range of the additives may be 10-30
percent. Other exemplary embodiments of composition of ingredients may
comprise 60-85 percent polymer. Exemplary polymers such as but not
limited to: SPF 918, polyurethane, etc. In yet other embodiments a
combination of the above may be used.

[0031] Other exemplary attributes may include: flexibility, viscous,
cohesive, brittle, tacky, erectness, spreading capabilities, required
thickness, etc. Drawing the SAR on the SARD may comprise the following
actions: create SAR; lay SAR; and adhere SAR on the surface of the SARD's
body. The drawing of the SARs may be done in a continuous motion, in a
segmented motion, and/or a combination of both motions. The flexible
material of the SARs ingredients and the ratio between them may influence
the different attributes of the flexible material. Exemplary ingredients
may include: different polymers, silica, ceramics, fillers, fiber, etc.
Exemplary ratios of combinations of different ingredients may be for UV
curing (i.e., see tables 1, and 2) and for thermal curing (i.e., see
tables 3, 4 and 5):

[0032] In some embodiments the flexible material of the SAR may be:
thermoplastic polymers, thermosetting polymers, metal, a combination of
them, and so on. Exemplary flexible material may comprise: Polyurethane,
having a hardness of 60-99 shore A, preferably, 80-99 shore A or
Polypropylene, etc. Optionally, the viscosity of the material as
deposited (drawn) may be between 1,000 cps and 145,000 cps, preferably
between 17,000 cps and 80,000 cps, etc.

[0033] Yet in some embodiments, the SAR may be a cutting SAR. According to
these embodiments, the edges of the SAR may be milled (scraped) in order
to form a sharpened edge adapted for cutting, for example. The milling
may be done by mechanical or optical equipment. In these embodiments, the
SARs may be have a hardness of 85 shore A and more or 35 shore D and
more. Exemplary materials that may be used are: polymers loaded with
glass fiber, carbon fiber, Kevlar fiber or fillers like silica, metal,
carbon black etc.

[0034] In exemplary embodiments, the SAR (surface-adhesive rule)
profile/shape may comprise different attributes. Exemplary attributes of
the SAR cross-section may be: a wide base, a non-symmetrical shape, a
cone shape, straight shape, and different combination of them. The shape
and attributes of the SAR may be determined according to different
required parameters. These parameters may include, but are not limited
to: the layout of the surface-adhesive-rule die (SARD); the distance
between different SARs; the direction from which harsh forces will strike
the SARs; the adhesive requirements; etc. The SART (surface-adhesive-rule
technology) may enable the SARs to have non-standard sizes if required.

[0035] In exemplary embodiments, including some of the embodiments
described in the present disclosure, the surface-adhesive-rule die's
(SARD) body may be made of flexible film. The flexible film may include
one or more types of polymers. Exemplary polymers that may be used
include, but are not limited to: polyester, polyamide, polycarbonate,
and/or a combination of these polymers or others. Furthermore, the
flexible film may include one or more additives. These additives may
include, but not limited to: silica, ceramics, metal, different fillers,
etc. Exemplary embodiments of the flexible film may comprise several
layers (co-layers). Each layer may be constructed of a different
material.

[0036] The surface-adhesive-rule die's (SARD) body may be associated with,
connected to, or joined with a substrate made from material other than
flexible film. Materials such as, but not limited to, metal, wood, etc.
Furthermore, the surface-adhesive-rule die's (SARD) body may have a flat
shape, cylindrical shape or any other shape. In addition, the SARD's body
may be flexible such that it can change its shape, for example from flat
to cylindrical so it can be wrapped around a drum, for example.

[0037] The flexible film of the SARD's body may have a strong enough
sustainability, firmness, inside-cohesion, robustness, and/or lifespan to
withstand the pressures and harsh operation which can be around a few ton
press force (1-10 ton, for example) in one or more directions during the
cutting/creasing/embossing operation of the cardboards. In other
exemplary embodiments, the SARD's body may be made of material other then
flexible film, and/or a combination of them. Furthermore, the
surface-adhesive-rule technology enables working without the need of
ejection (rebound) rubber around the surface-adhesive rule.
Advantageously, this aspect of the various embodiments saves time, money,
and rubber material.

[0038] The surface-adhesive-rule technology may comprise a novel flexible
surface-adhesive-rule counter die (SARCD). The SARCD body may comprise
flexible-counter film. The flexible-counter film may include one or more
types of polymers. Exemplary polymers that may be used include, but are
not limited to: polyurethane, EPDM (ethylene propylene diene Monomer
rubber), NBR (Nitrile butadiene rubber), acrylic rubber, silicone rubber,
SBR (Styrene-Butadiene-Rubber) etc. Furthermore, the flexible-counter
film may include one or more additives. These additives may include, but
not limited to: silica, ceramics metal, fillers, various fibers, slip
agent, carbon black, talc, etc. Exemplary embodiments the
flexible-counter film may comprise several layers. Each layer may be made
of different materials.

[0039] The surface-adhesive-rule counter die's (SARCD) body may be
associated with, joined to or connected to a material other then the
flexible-counter film. These materials may include, but not limited to
metal, wood, PET (Polyethylene terephthalate) film, sponge material (with
open or closed cells), etc. For example, the flexible-counter films may
be associated with, joined to or connected to a sponge material, and the
sponge material may be associated with, joined to or connected on its
other side to a PET (Polyethylene terephthalate) film base, and so on.
Furthermore, the surface-adhesive-rule counter die's (SARCD) body may
have a flat, cylindrical or any other shape. In addition, the SARCD's
body may be flexible such that it can change its shape, for example from
flat to cylindrical so it can be wrapped around a drum, for example. The
flexible-counter film may have a strong enough sustainability, firmness,
inside-cohesion, robustness, and/or lifespan to withstand pressure and
harsh operation. The surface-adhesive-rule counter die's (SARCD) may be
supplied/sold as a SARCD body, and/or as a SARCD body associated with,
joined to or connected to a drum or a flat base. As a non-limiting
example, the SCARD body associated with a flat or drum base by molding,
coating, attachment by grippers, etc.

[0040] The flexible-counter film may have additional attributes. Examples
of these additional attributes may include, but are not limited to:
flexibility, required thickness, resilience, required hardness, dimension
stability, coefficient of friction, sustainability, inside-cohesion,
robustness, life span, sponge attribute, wear-out resistance, etc.
Exemplary surface-adhesive-rule counter die (SARCD) may have a body that
is comprised of a flexible-counter film made of polyurethane at a
thickness of a few mm (1.1-3.7 mm, as a non-limiting example) with a
hardness of a few tens of shores (20-70 shore, as a non-limiting
example).

[0041] Exemplary embodiments of the flexible-counter film may be comprised
of several layers. Each layer of the flexible-counter film may be made
from or comprise different ingredients. Further, each layer of the
flexible-counter film may have different attributes. As a non-limiting
example, the lowest or bottom layer may be comprised of a material with
attributes that: have a high friction coefficient, are tacky, have an
affinity, and/or include a degree of firmness. Further, the highest or
top layer of the flexible-counter film may be comprised of a material
with attributes that: have a high resilience, have a degree of
flexibility, and/or are resistant to wearing out.

[0042] Even further, an intermediate layer of the flexible-counter film
may be comprised of a material with attributes that provide sponginess or
compression, etc. In some exemplary embodiments, the flexible-counter
film may also be comprised of a lattice with a pre-defined density of one
or more different fibers. Exemplary fibers in the lattice may include,
but are not limited to, metal fibers, carbon fibers, etc. In other
exemplary embodiments, the flexible-counter film may be notched. The
notches may be made in a variety of manners such as but not limited to by
a laser.

[0043] The SARCD flexible-counter film's ingredients and the ratio between
them may influence the different attributes of the flexible film.
Exemplary ingredients may include, but are not limited to: different
polymers, silica, ceramics, fillers, fiber etc.

[0044] The surface-adhesive-rule technology (SART) may provide a novel
surface to the flexible surface-adhesive-rule counter die's body (SARCD).
In exemplary embodiments, the surface of the flexible SARCD's body may be
a blank surface. A blank surface may be defined as a surface with no
trenches or pattern/layout. The flexible-counter film may be such that it
adapts itself to the SAR (surface-adhesive rule) that it will encounter.
This characteristic has the advantage of alleviating the need for
resources and time that is required in the creation of trenches on a
counter-die.

[0045] Further, the surface of the flexible surface-adhesive-rule counter
die's (SARCD) body may return to a blank surface after the dies (SARD and
SARCD) detach from each other (resilience attribute). Thus, the flexible
SARCD may be used for different surface-adhesive-rule dies (SARD). This
characteristic that can be employed in various embodiments also results
in reducing the cost and production time for the SARCD. In other
exemplary embodiments, the SARCD material may remember the pattern/layout
due to the press, this attribute may be achieved using thermoplastic
material, for example.

[0046] In alternate exemplary embodiments, the surface of the flexible
SARCD body may include one or more trenches. The trenches may be created
using a variety of different techniques. Exemplary techniques for
creating the trenches may comprise: using a laser, drawing negative,
extrusion, gnawing, molding, coating, etc. The SARCD may also be created
using a variety of different techniques. Techniques for creating the
SARCD may include, but not limited to: molding, coating, press/injection
molding, a combination of them, etc. More information on the different
techniques of creating the SARCD is disclosed below in conjunction with
the description of FIGS. 16-18.

[0047] The surface-adhesive-rule technology (SART) enables a user to
create a fine crease in the cardboard. This has been experimentally
tested and verified by the applicants. The creases achieved by use of the
SART exceed current industry standards and as such, it may result in
creating a new and higher (finer) standard. Furthermore, the SART
improves the quality of the pre-treated cardboard crease's surface. These
improvements may include significantly reducing the number and severity
of ply-cracks, for example. Thus, the SART performs at a level that
exceeds the present industry capabilities and standards.

[0048] In addition, the SART allows for new shapes of packages to be
created and at a higher aesthetic quality. This also has been
experimentally tested and verified by the applicants. The SART enables a
user to create new and different shapes of creasing/cutting/embossing and
different alignment of the creasing/cutting/embossing on the cardboard.
For example, the SART enables: the pre-treated creasing to be much more
refined; reduces ply-cracks and reduces the tearing of the cardboard;
etc.

[0049] The flexible film of the SARD's body and/or the flexible-counter
film of the SARCD's body, may be relatively immune to a changes in room
parameters and over a wider range of room parameters. For instance,
SARD's body and/or SARCD's body provide consistent results when room
parameters such as, but not limited to, temperature, humidity, light,
etc. vary or over a wide range of these parameters.

[0050] In exemplary embodiments of the present disclosure, the
surface-adhesive rules (SAR) may be bonded to the surface of the flexible
surface-adhesive-rule die's body by adhesion. Exemplary adhesion
techniques may include, but are not limited to, using an
intermediated-adhesive material between the SAR and the flexible SARD
body's surface. The intermediated adhesive material used may include, but
is not limited to: adcote 811 of DOW company, 238A+catalyst of MORCHEM
company, etc. Other exemplary embodiments of adhesion may be achieved by
adhesive attributes of the SAR and the surface of the flexible SARD's
body materials. Yet, in other exemplary embodiments, a combination of
these two, as well as other techniques may be implemented. Adhesive
attributes may include, but are not limited to: epoxy, oligomer, silicone
acrylate oligomer, adhesion promoter, photoinitiator.

[0051] Exemplary embodiments of the present disclosure provide a method
and system for bonding the SARs to the surface of the flexible SARD's
body during the course of making the surface-adhesive-rule die (SARD)
with the creation of its surface-adhesive rules (SAR) simultaneously. The
surface adhesive method and system may comprise: one or more
pre-adhesive-treatment methods and systems; one or more adhesive
substances; one or more adhesive spreading/laying of the adhesive
substances; one or more curing techniques; one or more
post-adhesive-treatments; and so on.

[0052] The type of the surface adhesive method and system utilized may be
determined based on a variety of parameters. These parameters may
include, but are not limited to: the SAR material; the material of the
surface of the SARD's body; the combination of the SAR material and the
material of the surface of the SARD's body; time requirements of the
surface-adhesive-rule technology (SART); and so on.

[0053] Different pre-treatment(s) may be done or applied before drawing
SARs. Exemplary pre-treatments that can be applied prior to the drawing
may include, but are not limited: different primers and primer
techniques; Ozone-shower; high voltage electric cord; electron beam;
plasma; flaming, etc. In exemplary embodiments, illuminating the flexible
SARD's body with UV light can be performed as a pre-treatment before
laying and adhering the surface-adhesive rules (SAR), for example.

[0054] In an exemplary embodiment, the intermediated-adhesive material may
be placed, spread, sprayed, coated, painted or otherwise placed onto the
surface of the flexible SARD body before the laying of the SARs. In an
alternate embodiment, the intermediated-adhesive material may be placed,
spread, sprayed, painted or otherwise placed on the surface of the
flexible SARD's body during the drawing of the SARs. The
intermediated-adhesive material may be placed, spread, sprayed, painted
or otherwise placed on the surface of the flexible SARD's body in
different methods and systems. Exemplary methods and systems may be:
spreading the intermediated-adhesive material by an application head
associated with or controlled by a leading mechanism.

[0055] The novel surface-adhesive-rule technology (SART) enables a
complete surface-adhesive-rule die (SARD) to be automatically created,
while simultaneously drawing its plurality of surface-adhesive rules
(SARs). Exemplary embodiments of the system and method of the
surface-adhesive-rule technology may include a rule-drawer.

[0056] The rule-drawer may operate to automatically draw the
surface-adhesive rules (SARs) onto the surface of the flexible
surface-adhesive-rules die (SARD) at the desired locations. The process
of drawing the rules may comprise one or more of the following actions:
create the SAR; lay the SAR; adhere the SAR onto the surface of the
SARD's body. The drawing of the SARs may be done in a continuous motion,
in a segmented motion, and/or a combination of both motions as well as a
variety of other techniques.

[0057] An exemplary embodiment of a rule-drawer may comprise: one or more
drawing-heads, a controller, and a leading mechanism. The drawing-head
may be an automatic drawing-head associated with the leading mechanism.
The leading mechanism, under the control of the controller may operate to
move elements of the drawing-head to different locations and in different
directions, for example. The leading mechanism may be a mechanical arm,
one or more rails, etc. The controller may control the drawing head as
well as the leading mechanism, for example. For instance, the controller
may operate to cause the leading mechanism to move the drawing head to a
desired location, then trigger the drawing head to begin drawing.

[0058] The controller may be integral to a computer (such as software,
firmware etc. Software may be embodied on a computer readable medium such
as a read/write hard disc, CDROM, Flash memory, ROM, or other memory or
storage, etc. In order to execute a certain task a software program may
be loaded to an appropriate processor as needed) or operated by a
computer, for example. As a non-limiting example of the controller being
integral to a computer, the computer may be loaded with a job
description. The job description may include: the type of the
surface-adhesive rules (SAR), the type and thickness of the cardboard,
the layout of the surface-adhesive-rule die (SARD), etc. The layout of
the SARD may include, the placement of each SAR and its type, for
example. According to the layout of the SARD, the controller may command
and automatically control the leading mechanism of the rule-drawer for
drawing the SARs on the SARD's body. The controller may control other
modules of the surface-adhesive-rule technology (SART). Thus, exemplary
embodiments of the present disclosure may include the above-described
novel method and system of creating an automatic direct-computer-to-die
(DCTD) surface-adhesive-rule technology (SART).

[0059] The computer of the SART may further comprise a stored look-up
table. The stored look-up table may comprise different information.
Exemplary information may include, but is not limited to: information
regarding the surface-adhesive rule's profile according to required
cardboard thickness; the required cardboard length; the cardboard
coefficient of friction (COF); the information regarding the required
ingredients for the flexible material for a required cardboard; the
information regarding the required ingredients for the flexible material
for a required function (cutting/creasing/embossing); the profile of SAR;
the nozzle type; and so on.

[0060] In an exemplary embodiment, the drawing-head or drawing-heads of
the rule-drawer may comprise a cartridge. Although the description may
refer to a single drawing-head, it should be appreciated that in various
embodiments, more than one drawing head may be utilized. The cartridge of
the drawing-head may contain flexible material. The drawing-head may
further comprise a nozzle with one or more predefined orifice shapes. The
orifice shapes may be selected according to a required profile of the
surface-adhesive rules (SAR), for example. The drawing-head may further
comprise a pressure-actuator. The pressure-actuator may be used to
dispense the flexible material out of the cartridge and through the
nozzle's orifice toward the required placement on the surface of the
die's body thereby creating the surface-adhesive rule and die.

[0061] The pressure-actuator employed in various embodiments may be of
different types. Exemplary types of the pressure-actuator may include,
but are not limited to: an air-pump actuator, a screw-pump actuator, a
piston actuator, an electrical pump actuator, a cogwheel actuator, an
inject actuator etc. Exemplary embodiments of a pressure-actuator may
comprise a combination of one or more types of actuators. There may be
one or more pressure-actuators associated with one or more modules of the
rule-drawer, for example. In exemplary embodiments, the pressure-actuator
may have suction capabilities or functionality as well.

[0062] The nozzle of the drawing-head may have one or more orifices. The
orifice may determine the surface-adhesive rule profile/shape or may be
selected to obtain a desired profile/shape. The orifice may be located at
the bottom of the nozzle, at the side of the nozzle, on an edge of the
nozzle, or a combination of multiple placements, etc. In exemplary
embodiments, the nozzle may be quickly and easily disassembled or
detached from the drawing-head and a different nozzle may be assembled or
attached to the drawing-head. The inside of the nozzle and/or orifice may
have a coating that operates to reject or repel the flexible material.
Advantageously, this characteristic helps to prevent clogging or
blockage, either partial or complete, of the orifice. The shape and
placement of the orifice may be determined according to different
criteria. Exemplary criteria may include, but is not limited to: adhesive
requirements of the SAR to the surface of the SARD's body; the
drawing-termination technique used; the required surface-adhesive rule
profile; and so on.

[0063] During the drawing of a SAR the nozzle may be placed at a
predefined angle and height from the surface of the SARD's body,
according to commands from the controller, for example. The angle and
height of the nozzle may be determined according to different criteria.
Exemplary criteria may include, but is not limited to: orifice location;
the flexible material of the SAR; the distance from an adjacent SAR; and
so on. In exemplary embodiments, the angle and height may change during
the drawing of the SARs. In exemplary embodiments, the flexible material
may be ejected from the orifice in a "spitting" manner, near a corner for
example.

[0064] The cartridge may be implemented in a variety of techniques. An
exemplary embodiment of a cartridge may be a cylindrical shape with a
specific volume capacity (e.g. 30-800 cc volume). In an alternate
embodiment, the cartridge may be in a predefined shape, similar to the
shape of the nozzle's orifice, for example. Further, in exemplary
embodiments, the cartridge may be associated with or fed from a larger
volume container, which can load the cartridge with flexible material at
predefined times, continuously and/or when needed. In exemplary
embodiments, a mixer may be associated with the cartridge. The mixer may
mix the flexible material inside the cartridge at predefined times,
continuously and/or when needed. The mixer may further comprise a heater,
for example.

[0065] The inside of the cartridge may have a coating that operates to
reject or repel the flexible material. Advantageously, this
characteristic promotes to flow of the flexible material toward the
nozzle. In exemplary embodiments, there may be one or more cartridges
working together on the drawing of a SAR, or on the creation of different
SARs, and so on. An exemplary embodiment of a multiple-compartments
cartridge may contain, separately, one or more ingredients of the
flexible material. In an alternate embodiment, each compartment may
comprise a different flexible material, for a different layer of the
co-layer, for example.

[0066] In alternate embodiment the co-layer may be created in phases. It
should also be appreciated than in some embodiments, a bank of cartridges
may utilized to house different ingredients and flexible materials and,
the controller or rule-drawer may operate to select one or more
ingredients to be mixed, or different materials to be ejected through the
nozzle depending on the particular requirements. For example, cartridges
may include various additives that can provide different characteristics
to the materials being applied. If quick drying is required in a
particular application, additives may be pulled from a cartridge that may
provide such a characteristic. Likewise, different pigmentations can be
utilized, different levels of viscosity, etc., can be obtained in real
time by the controller controlling the volume of particular additives or
substances from the cartridges. In some embodiments, a heating element
may also be utilized to heat the content of the cartridges to a desired
temperature.

[0067] The cartridge may further comprise a combiner. In exemplary
embodiments, the combiner may combine the different ingredients and/or
flexible material, for example. The combiner may comprise a slot or an
aperture through which the combined material may be output. The
controller of the rule-drawer for example, may control the quantities of
each component, for example. This can be accomplished in a variety of
manners such as controlling the flow-rate from a cartridge by adjusting
the size of an opening valve from the cartridge, the amount of pressure
applied to the cartridge, etc.

[0068] In an exemplary embodiment, the drawing-head may further comprise
one or more adhesive-cartridges and an adhesive-nozzle that may
spread/spray adhesive substance on the required areas.

[0069] In exemplary embodiments the controller, of the rule-drawer for
example, may be responsible to control and synchronize the velocity of
the -leading mechanism of the rule-drawer to the placement and phase of
the SAR drawing process. For example, at the beginning of the drawing of
the surface-adhesive rule, the velocity of the leading mechanism may be
slower than the velocity at the middle of the drawing of the
surface-adhesive rule.

[0070] In some embodiments, the controller may be responsible for
controlling and synchronizing the amount of pressure to be imposed by the
pressure-actuator on the flexible material according to the placement and
phase of the SAR drawing process. For example, at the beginning of the
drawing of the surface-adhesive rule less pressure may be imposed then
the imposed pressure at the middle of the drawing of the surface-adhesive
rule.

[0071] In exemplary embodiments, the controller may be responsible for
controlling and/or synchronizing the amount of pressure to be imposed by
the pressure-actuator and the velocity of the leading mechanism according
to a flow index of the flexible material. The flow index may be the
amount of flexible material that is output through the nozzle's orifice
at a predetermined time with a predetermined pressure, for example. The
flow index may be influenced by the different attributes of the flexible
material. Attributes such as, but not limited to: viscosity, thickness,
tackiness, size of particles, a combination of any of these attributes as
well as others.

[0072] In an exemplary embodiment, the leading mechanism may move in a
plurality of directions on one or more axes. For instance, the leading
mechanism may move in multiple directions along the X, Y and/or Z axes.
In an alternate embodiment, the leading mechanism may move only along two
axes, such as the X and Y axes. Exemplary embodiments of the
surface-adhesive-rule technology may further comprise a conveyor on which
the body of the SARD is associated with during the process. The conveyor
may move in multiple directions along one or more axes and/or in a
circular direction, for example. The controller may control the conveyor
velocity and direction of movement, for example. In an alternate
embodiment, the surface-adhesive-rule technology may further comprise a
drum on which the SARD may be positioned. The controller may control the
drum velocity and direction of movement, for example. Further, it will be
appreciated that a combination of a moving leading mechanism for moving
the drawing-head and a mechanism for moving the SARD may be employed. For
instance, the leading mechanism may move the drawing head in multiple
directions on the X axes while the conveyor moves the SARD in multiple
directions on the Y axes. Other combinations are also anticipated.

[0073] Exemplary embodiments of the present disclosure may further
implement different hardening techniques. The hardening techniques may
include, but are not limited to: temperature treatment, light curing (UV,
IR, visible light), chemical curing, etc. In some exemplary embodiments,
the flexible material may comprise thermosetting polymers and may be
hardened by heating, for example. Alternatively or additionally, the
flexible material may comprise thermoplastic polymers and hardening of
the flexible material may be accomplished by cooling the material, for
example. Some flexible materials may include photo-initiator ingredients
that enable curing by UV illumination, for example. In other exemplary
embodiments, the material may be cooled or harden by itself. In yet other
exemplary embodiment, the flexible material may be hardened by electron
beam.

[0074] Exemplary embodiments of the present disclosure may comprise a
method and apparatus that will isolate the flexible material that has not
yet been placed (in the cartridge and nozzle, for example) from the
origin of the hardening energy. A divider may be placed between the
origin of the hardening energy and the cartridge/nozzle at the time of
hardening, for example.

[0075] In some exemplary embodiments, the rule-drawer may further comprise
a flow-intermissioner. The flow-intermissioner may be passive, active, or
a combination of both. The flow-intermissioner may be implemented as an
apparatus, a method, or a combination of both. The flow-intermissioner
may, when required, stop/pause the output of the flexible material during
the drawing of the surface-adhesive rules. The controller may control the
operation of the flow-intermissioner. Exemplary embodiments of the
flow-intermissioner may be implemented as different shutters. There may
be one or more shutters. The shutter may be associated with one or more
modules of the rule-drawer. Exemplary shutters may include, but are not
limited to: a knife, an air-knife, a plug, a stopper, etc.

[0076] Exemplary embodiments of a flow-intermissioner may include a method
in which the nozzle is spun sharply around its center while the
pressure-actuators stop outputting the flexible material, for example.
The method may further comprise adding certain ingredients that will
accelerate the breaking/cutting of the flexible material (brittle
attribute) at the moment of required termination. Exemplary ingredients
may include, but are not limited to: silica, air bubbles, water drops,
etc. Other embodiments may implement suction actions.

[0077] The surface-adhesive-rule technology (SART) may further comprise a
self-maintained-cleaning mechanism. The self-maintained-cleaning
mechanism may be a part of the rule-drawer, such as an additional
cartridge that stores cleaning material, for example. In other exemplary
embodiments, the self-maintained-cleaning mechanism may be external to
the rule-drawer. The self-maintained-cleaning mechanism may work at
pre-defined times and/or when needed.

[0078] Other exemplary embodiments of the surface-adhesive-rule technology
(SART) may be implemented using magnetic forces. Exemplary methods of
constructing a die may be by bonding SARs to the body of the SARD by
magnetic forces. In some embodiments, small pieces of magnetic material
may be deposit on the SARD's body and attracted to it by magnetic force.
An adhesive may be added between the magnetic material and body.
Exemplary sizes of the pieces of the deposited magnetic material, may be
about 1 mm on each side, for example. The pieces of material may be
deposited adjacent to each other, so as to form a desired layout of SARs.
In some embodiments, the SARD body may include a magnetic force only on
the desired layout, for example. Exemplary peel strength between the
pieces of material and the body may be about 13 gr/mm2.

[0079] Yet other exemplary embodiments of the SART (surface-adhesive-rule
technology) may be implemented by coating the surface of the SARD's body
with a low surface tension material and the locations where SARs are to
be formed are coated with a high surface tension material. The flexible
material may be deposited onto the body of the die. Due to the high
surface tension material at the locations of the SARs, the flexible
material may coalesce from the low surface tension areas to the high
surface tension areas. This characteristic creates surface-adhesive rules
at the desired locations. Optionally, the material may be deposited only
on areas surrounding the high surface tension areas. In some embodiments,
the SARs may then be hardened and/or adhered to the die.

[0080] Unless otherwise defined, all technical and/or scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which the disclosure pertains. In case there
is a conflict in the definition or meaning of a term, it is intended that
the definitions presented within this specification are to be
controlling. In addition, the materials, methods, and examples that are
presented throughout the description are illustrative only and are not
necessarily intended to be limiting.

[0081] Reference in the specification to "one embodiment" or to "an
embodiment" means that a particular feature, structure, or characteristic
described in connection with the embodiment is included in at least one
embodiment of the disclosure, and multiple references to "one embodiment"
or "an embodiment" should not be understood as necessarily referring to
the same embodiment or all embodiments.

[0082] Implementation of the method and/or system of embodiments of the
disclosure can involve performing or completing selected tasks manually,
automatically, or a combination thereof. Moreover, according to actual
instrumentation and equipment of embodiments of the method and/or system
of the disclosure, several selected tasks could be implemented by
hardware, by software or by firmware or by a combination thereof and with
or without employment of an operating system. Software may be embodied on
a computer readable medium such as a read/write hard disc, CDROM, Flash
memory, ROM, etc. In order to execute a certain task, a software program
may be loaded into or accessed by an appropriate processor as needed.

[0083] These and other aspects of the disclosure will be apparent in view
of the attached figures and detailed description. The foregoing summary
is not intended to summarize each potential embodiment or every aspect of
the present disclosure, and other features and advantages of the present
disclosure will become apparent upon reading the following detailed
description of the embodiments with the accompanying drawings and
appended claims.

[0084] Furthermore, although specific embodiments are described in detail
to illustrate the inventive concepts to a person of ordinary skill in the
art, such embodiments are susceptible to various modifications and
alternative forms. Accordingly, the figures and written description are
not intended to limit the scope of the inventive concepts in any manner.

BRIEF DESCRIPTION OF THE DRAWINGS

[0085] Exemplary embodiments of the present disclosure will be understood
and appreciated more fully from the following detailed description, taken
in conjunction with the drawings in which:

[0087] FIG. 2a-b are schematic illustrations of simplified block diagrams
with relevant elements of an exemplary surface-adhesive-rule die (SARD),
according to exemplary teaching of the present disclosure;

[0088] FIGS. 3a-f are schematic illustrations a plurality of simplified
diagrams with relevant elements of exemplary surface-adhesive-rule (SAR)
profiles, according to exemplary teaching of the present disclosure;

[0089]FIG. 4 depicts a schematic diagram with relevant elements of an
exemplary surface-adhesive-rule technology (SART) system in accordance
with some exemplary embodiments of the present disclosure;

[0090] FIG. 5 depicts a schematic diagram with relevant elements of
another exemplary surface-adhesive-rule technology (SART) system for
producing a die in accordance with some exemplary embodiments of the
present disclosure;

[0091] FIG. 6 depicts a schematic diagrams with relevant elements of an
exemplary nozzle and cartridge of a rule-drawer, according to exemplary
teaching of the present disclosure;

[0092] FIGS. 7a-b are schematic illustrations of simplified diagrams with
relevant elements of an exemplary nozzles and cartridges of a
rule-drawer, according to exemplary teaching of the present disclosure;

[0093] FIGS. 8a-f are schematic illustrations of a plurality of simplified
diagrams with relevant elements of exemplary pressure actuators of a
rule-drawer, according to exemplary teaching of the present disclosure;

[0094] FIGS. 9a-b are schematic illustrations of different co-layer
creations, according to exemplary teaching of the present disclosure;

[0095] FIGS. 10a-d are schematic illustrations of a flowchart showing
relevant acts of an exemplary method of a drawing process, according to
exemplary teachings of the present disclosure;

[0096]FIG. 11 depicts a simplified diagram with relevant elements of an
alternative exemplary surface-adhesive-rule technology (SART) system in
accordance with some exemplary embodiments of the present disclosure;

[0097] FIG. 12 depicts a schematic illustration of relevant elements of
yet another exemplary surface-adhesive-rule technology (SART) system
depositing pieces of material in accordance with some exemplary
embodiments of the disclosure;

[0098]FIG. 13 depicts a schematic illustration of relevant elements of an
exemplary SAR die (SARD) produced with the SART system shown in FIG. 12,
according to exemplary teaching of the present disclosure;

[0099] FIGS. 14a-c are schematic illustrations of SAR dies (SARDs)
produced in accordance with yet other embodiments of the present
disclosure;

[0100]FIG. 15 depicts a schematic illustration of relevant elements of
another exemplary surface-adhesive-rule technology (SART) system,
according to exemplary teaching of the present disclosure;

[0101] FIG. 16a-b depicts schematic illustration of relevant elements of a
portion of an exemplary embodiment of a molding system for creating a
SARCD and/or SARD body, according to exemplary teaching of the present
disclosure;

[0102] FIG. 17a-b depicts schematic illustration of relevant elements of a
portion of an exemplary embodiment of a press system for creating a SARCD
and/or SARD body, according to exemplary teaching of the present
disclosure;

[0103]FIG. 17c depicts schematic illustration of relevant elements of a
portion of an exemplary embodiment of a inject/extruder system for
creating a SARCD and/or SARD body, according to exemplary teaching of the
present disclosure;

[0104]FIG. 18 depicts schematic illustration of relevant elements of a
portion of an exemplary embodiment of a coating system for creating a
SARCD and/or SARD body, according to exemplary teaching of the present
disclosure; and

[0105]FIG. 19 depicts schematic illustration of relevant elements of a
portion of an exemplary embodiment of a SART controller, according to
exemplary teaching of the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0106] Turning now to the figures in which like numerals and/or labels
represent like elements throughout the several views, exemplary
embodiments of the present disclosure are described. For convenience,
only some elements of the same group may be labeled with numerals. The
purpose of the drawings is to describe exemplary embodiments and is not
for production purpose. Therefore features shown in the figures are for
illustration purposes only and are not necessarily drawn to-scale and
were chosen only for convenience and clarity of presentation.

[0107] FIG. 1a depicts a block diagram with relevant elements of an
exemplary common prior art steel-rule die 100. Steel-rule die 100 may
comprise a body 110, and a plurality of steel-rules: steel-rule 112 and
steel-rule 114, for example. Steel-rules 112 and 114 may be cutting
rules, creasing rules, embossing rules, etc. The body 110 may be made of
hard-wood material, for example.

[0108] FIG. 1b depicts cross-sectional view of the exemplary prior art
steel-rule die 100 of FIG. 1a taken at line A-A. Steel-rule 112 may be
jammed deeply inside the body 110 of the steel-rule die, even extending
to the point that is all the way through the body 110. Steel-rule 114 may
be jammed inside part of the steel-rule die's body 110.

[0109] FIG. 2a schematically illustrates a simplified portion of a block
diagram with relevant elements of an exemplary surface-adhesive-rule die
200 (SARD). The surface-adhesive-rule die 200 (SARD) may comprise a body
210, and a plurality of surface-adhesive rules (SAR): SAR 212 and SAR
214, for example. Surface-adhesive rules (SAR) 212 and 214 may be of
different types. Exemplary SAR types may be: cutting SAR; creasing SAR;
embossing SAR; etc. Henceforth, throughout the description, drawings and
claims of the present disclosure the terms cutting SAR, creasing SAR,
embossing SAR, etc. may be used interchangeably and the term SAR used by
itself may refer to any of these types.

[0110] SAR 212 and SAR 214 may be made of flexible material, for example.
The flexible material may be gel or liquid like material. The flexible
material may include one or more different types of polymers and/or
different combinations of polymers. Exemplary polymers that may be used
include, but are not limited to: polyester, polyamide, polycarbonate,
polyurethane, acrylic, polypropylene, polyethylene, etc. Furthermore, the
flexible material may include one or more additives. The additives may
include, but are not limited to: silica, ceramics, metal, various fibers,
different fillers, etc. Exemplary embodiments SAR may comprise several
layers (co layer), and each such layer be constructed from a different
material or, one or more layers may be constructed from different
material.

[0111] The exemplary SAR 212 and SAR 214 may have a strong enough
sustainability, firmness, inside-cohesion, robustness, and/or lifespan to
withstand the pressure and harsh operation of high pressure press force
in one or more directions on the SAR during the
cutting/creasing/embossing operation of numerous cardboards. The pressure
press force may be around a few tons. 1-10 ton pressure press force, for
example.

[0112] The flexible material may have additional attributes as well.
Exemplary attributes may include, but are not limited to: flexibility,
tackiness, spreading capabilities, required thickness, etc. Different
ingredients in the flexible material, and the ratio between these
ingredients influence the presence and/or ranges of the different
attributes. Exemplary ingredients may include, but are not limited to:
different polymers, silica, ceramics, fillers, fiber etc. Exemplary
ratios in the combinations of different polymers, silica, ceramics,
fillers are illustrated in the following tables:

[0113] In some embodiments the flexible material of the SAR may be:
thermoplastic polymers, thermosetting polymers, metal, a combination of
them, and so on. Exemplary flexible material may comprise: Polyurethane,
having a hardness of 60-99 shore A, preferably, 80-99 shore A or
Polypropylene, etc. Optionally, the viscosity of the material as
deposited (drawn) may be between 1,000 cps and 145,000 cps, preferably
between 17,000 cps and 80,000 cps, etc.

[0114] Yet in some embodiments, the SAR may be a cutting SAR. According to
these embodiments, the edges of the SAR may be milled in order to form a
sharpened edge adapted for cutting, for example. The milling may be done
by mechanical or optical equipment. In these embodiments, the SARs may be
have a hardness of 85 shore A and more or 35 shore D and more. Exemplary
materials that may be used are: polymers loaded with glass fiber, carbon
fiber, Kevlar fiber or fillers like silica, metal, carbon black etc.

[0115] The exemplary body 210 of the surface-adhesive-rule die (SARD) 200
210 may be made of or comprise a flexible film. The flexible film may
include one or more types of polymers. Exemplary polymers that may be
used include, but are not limited to: polyester, polyamide,
polycarbonate, and/or a combination of one or more of these polymers as
well as other polymers and non-polymers. Furthermore the flexible film
may include one or more additives. The additives included in the flexible
film may include, but are not limited to: silica, ceramics, metal,
different fillers, etc. Exemplary embodiments of the flexible film may
have one or more layers and, each layer may utilize or contain a
different material than one or more of the other layers. In some
exemplary embodiments, the flexible film may be a commercial one.

[0116] Exemplary flexible films that may be used in the body 210 of a
surface-adhesive-rule die 200 (SARD) may include, but are not limited to:
PET (Polyethylene terephthalate), PA (Polyamide), polypropilen, stainless
steel, Aluminum (Al) and/or a combination of one or more of these
materials as well as others. Exemplary suppliers for such materials are:
HANITA Company (an Israeli company), SKC Company, ALCAM VAW Company, etc.
Some exemplary embodiments of the body 210 of the surface-adhesive-rule
die 200 (SARD) may be comprised of a combination of two or more flexible
films. Exemplary combinations may include, but are not limited to: 23
micron thickness of PET associated to 25 micron thickness of Al; and/or
25 micron thickness of PET associated to 25 micron thickness of Al;
and/or 36 micron thickness of PET associated to 45 micron thickness of
PA; and/or 23 micron thickness of PET associated to 15 micron thickness
of PA and 18 micron thickness of Al; etc.

[0117] The body 210 of the SARD may be associated with, adhered to or
otherwise combined with a substrate made of material other then flexible
film. These other materials may include, but not limited to: metal, wood,
plastic, etc. Furthermore, the body 210 of the SARD may have a flat,
cylindrical or other shape. In addition, the body 210 of the SARD may be
flexible such that it's shape can be n changed, for example from flat to
cylindrical to be wrapped around a drum, for example.

[0118] The body 210 of the SARD may have a strong enough sustainability,
firmness, inside-cohesion, robustness, and/or lifespan to withstand the
pressure and harsh operation which can be around a few tons of press
force (1-10 ton, for example) in one or more directions during the
cutting/creasing/embossing operation of the cardboards. In other
exemplary embodiments, the body 210 of the SARD may be made of material
other then flexible film, and/or a combination of various materials.

[0119] The flexible film may have additional attributes such as being
flexible, tacky, spreadable, meeting required thicknesses, etc. Different
ingredients in the flexible film, and the ratio between these ingredients
influence the ratio or the characteristics of the different attributes.
Exemplary ingredients may include, but are not limited to: different
polymers, silica, ceramics, fillers, fiber etc.

[0120] FIG. 2b depicts a cross-sectional view of the exemplary
surface-adhesive-rule die 200 (SARD) taken at line A-A. Exemplary SAR 212
and SAR 214 may be bonded to the surface of the body 210 of the SARD by
adhesion. Exemplary adhesion techniques may include using an
intermediated-adhesive material between the SAR (212 and/or 214) and the
surface of the body 210 of the SARD. Intermediated adhesive materials may
include, but are not limited to: adcote 811 of DOW company, 238A+catalyst
of MORCHEM company, etc. Other exemplary embodiments of adhesion may be
achieved by adhesive attributes of the SARs 212 and 214 materials and the
materials used in the body 210 of the SARD. Adhesive attributes may
include, but are not limited to: epoxy, oligomer, silicone acrylate
oligomer, adhesion promoter, photoinitiator. In some embodiments, the
bonding may be done by hardening, such as thermal curing, chemical
curing, UV curing, etc. Yet in other exemplary embodiments a combination
of the two or more techniques may be implemented and other techniques are
also anticipated.

[0121]FIG. 3a schematically illustrates a simplified diagram with
relevant elements of an exemplary surface-adhesive-rule die (SARD) 300a.
The SARD 300a may comprise a body 310 and a surface-adhesive rule (SAR)
312. The SAR 312 may be adhered to the surface of the body 310. FIG. 3b
schematically illustrates a simplified diagram with relevant elements of
an exemplary surface-adhesive-rule die (SARD) 300b, in which the shape of
a surface-adhesive rule (SAR) 314 may comprise a wide base 318, and a
rounded-shape top edge 316.

[0122] The wide base 318 may improve the bonding of the SAR 314 to the
body 310 of the SARD 300b. The wide base 318 may further enhance the
ability of SAR 314 to withstand the numerous forces that may be applied
during cutting/creasing/embossing operations. The shape of the top edge
of the SAR 314 may match the functionality of the SAR 314. For example,
the rounded-shape edge 316 may be used for creating crease lines on the
surface of a cardboard.

[0123]FIG. 3c illustrates another exemplary embodiment of a SARD 300c.
The illustrated SARD 300c may comprise a SAR 320 with a sharp top edge
322. The shape of the top edge of the SAR 320 may match the functionality
of the SAR 320. For example, the sharp edge 322 may be used for creating
cutting lines on the surface of a cardboard. The SAR 320 may further
comprise shoulder-like sides 324. The shoulder-like sides 324 enhance the
ability of the SAR 320 to withstand the numerous forces during
cutting/creasing/embossing operations. In some exemplary embodiments the
sharp edge may be achieved by further milling (scraping) the edge after
hardening the SAR.

[0124]FIG. 3d schematically illustrates yet another simplified diagram
with relevant elements of an exemplary SARD 300d. The SARD 300d may
comprise a co-layer SAR 326. The co-layer SAR 326 may be comprised of 3
different types of layers, for example. One type of a layer for the base
330, another type of a layer for the shoulder-like sides 328, and a third
type of a layer for the rest of the body of the SAR 329 and its top edge.

[0125] Each of the co-layers in the illustrated SAR 326 may be made of
different materials or, one or more co-layers may be different from the
other co-layers. Each co-layer may have a different: shape;
cross-section; width; comprise different polymer types and/or additives;
etc. Each co-layer may also have a different required attributes. For
example, the lower base layer 330 may be required to have better adhesive
attributes, the highest layer 329 may be required to have more elastic
attributes, the shoulder-like sides may be required to have more firmness
attributes 328, and so on. Other exemplary embodiments of co-layered SARs
may have a different number of co-layers and different configurations of
shapes and attributes.

[0126]FIG. 3e illustrates yet another exemplary embodiment of a SARD
300e. The illustrated SARD 300e may comprise a SAR 332 with an
asymmetrical shape. SAR 332 may be comprised of a one shoulder-like side
334 and an asymmetrical base 336, for example. An asymmetrical SAR may be
used when drawing adjacent SARs. FIG. 3f illustrates an exemplary
embodiment of a SARD 300f. The SARD 300f may be comprised of a SAR 338
with a trapezoid-like shape top edge 340. The trapezoid-like shape top
edge 340 may be used as a cutting SAR in a rotary system, for example. It
should be appreciated that in other exemplary embodiments, different
combinations of two or more different profile SARs, and/or profile types
other then the SARs depicted in FIG. 3a-3f may be used.

[0127]FIG. 4 depicts a schematic diagram with relevant elements of a
portion of an exemplary surface-adhesive-rule technology (SART) utilizing
a rotary system 400. The surface-adhesive-rule technology's (SART) rotary
system 400 may be used for drawing a plurality of surface-adhesive rules
(SAR) 460-463 on the surface of a surface-adhesive-rule die's (SARD) body
420. The SARs 460-463 may protrude from the surface of the SARD's body
420 and may have different shapes and sizes. The SARs 460-463 may be
functional and configured for cutting, creasing, embossing, etc. and/or a
combination of two or more of these functions.

[0128] Surface-adhesive-rule technology's (SART) rotary system 400 may
include a drum 410 on which the SARD's body 420 may be positioned. The
body 420 of the SARD may be associated with or joined to the drum 410
using a variety of techniques including, but not limited to: adhesion,
gripers, molding, coating, etc. In exemplary embodiments, the body 420 of
the SARD may be removed from the drum 410 after the SARs 460-463 are
created. In other exemplary embodiments, the body 420 of the SARD may be
left on the drum 410, to be used for cutting/creasing/embossing
cardboards operations in a rotary system, for example. In some exemplary
embodiments, SART's rotary system 400 may include one or more drums.

[0129] A similar SART's rotary system 400 may be used for producing a
SAR-counter die (SARCD). The SAR-counter die (SARCD) may be associated
with the drum 410 in a similar ways as described elsewhere herein with
regards to the body 420 of the SARD. In an exemplary embodiment, the
SART's rotary system 400 may produce one flexible film layer to act as a
SAR-counter die (SARCD). In alternate embodiments, the SART's rotary
system 400 may produce a plurality of different flexible film layers to
act as a SARCD. In yet another exemplary embodiment, the SART's rotary
system 400 may produce only portions of the surface of the SAR-counter
die's body, and so on. Other exemplary embodiments of producing a
SAR-counter die (SARCD) are disclosed in conjunction with the description
of FIGS. 16, 17 and 18 for example.

[0130] Exemplary SART's rotary system 400 may roughen the surface of the
SARCD's body and/or the surface of the body 420 of the SARD using
different tools. These tools may include, but are not limited to: a
scraper, a laser, etc. Further, the SART's rotary system 400 may engrave
a desired layout of trenches with a laser or mechanical tool, for
example. In alternate exemplary embodiments, the SARCD body's surface may
not cover the entire surface of the die's body. For example, it may be
just two raised areas. The two raised areas may be drawn, molded, coated,
etc.

[0131] In exemplary embodiments of the present disclosure, the SARCD's
body and/or the SARD's body 420 may be made of flexible film. The
flexible film may include one or more types of polymers. Exemplary
polymers that may be used include, but are not limited to: polyester,
polyamide, polycarbonate, and a combination of these or other polymers or
polymer like substances. Furthermore, the flexible film may include one
or more additives. These additives may include, but are not limited to:
silica, ceramics, metal, different fillers, etc. Exemplary embodiments of
the flexible film may comprise several layers. Each layer may comprise
different materials.

[0132] The flexible film of the SARCD's body may have a strong enough
sustainability, firmness, inside-cohesion, robustness, and lifespan to
withstand the pressure and harsh operation which can be around a few tons
of press force in one or more directions during the
cutting/creasing/embossing operation of the cardboards. The SARCD's body
may be associated with a substrate made of other material. These
materials may include, but are not limited to metal, wood, plastic, etc.

[0133] The SAR 460-463 on the body 420 of the SARD may be flexible enough
to bend even after hardening, but still rigid enough to serve their
purposes of cutting, creasing and/or embossing.

[0134] SART's rotary system 400 may further include one or more
rule-drawers. Exemplary embodiments of the rule-drawer may comprise: a
drawing head 435, a controller 470, and one or more rails 430. The
drawing head 435 may comprise: at least one nozzle 440, at least one
cartridge 445 fluidly associated with the nozzle 440. The nozzle 440 may
be associated with the rail 430. In exemplary embodiments, the nozzle 440
may slide upon the rail 430. In exemplary embodiments, the cartridge 445
is associated with the rail 430 as well. In other exemplary embodiments
the cartridge 445 may be independent from the rail 430. Cartridge 445 may
comprise flexible material that will be output by nozzle 440, thus
drawing SARs 460-463, for example.

[0135] In exemplary embodiments, the cartridge 445 and the nozzle 440 may
be associated with or controlled by a motor for moving the cartridge 445
and/or nozzle 440 back and forth on rail 430 in a direction indicated by
arrow 450. In addition, the nozzle 440 may be adapted to rotate in the
directions indicated by arrows 452. Optionally, nozzle 440 may also move
up and down in the directions indicated by arrows 454. It should be
noted, in some embodiments, the drawing-head 435 may be used as a single
unit, while in other embodiments the nozzle 440 and/or the cartridge 445
may be moved independent from each other.

[0136] Drum 410 may be adapted to rotate in a counter-clockwise direction
indicated by arrow 455. Optionally, drum 410 may rotate in a direction
opposite to the direction indicated by arrow 455 (i.e., clockwise), and
yet in some exemplary embodiments, the drum 410 may rotate in both
directions. Further, the drum 410 may also be configured to move
laterally in relationship to the rail. The controller 470 may operate to
control and coordinate the movement and operations of the different
modules or elements, as well as the operations of the SART's rotary
system 400. For instance, the controller 470 may operate to control the
rotation of the drum 410, the movement of the nozzle 440 and the
cartridge 445; etc. The controller 470 may also instruct and control the
nozzle 440 and cartridge 445 to deposit flexible material on SAR die's
body 420 in order to draw a desired layout of SAR 460-463.

[0137] The nozzle 440 may output flexible material while moving in
different directions. Exemplary directions may include, but are not
limited to: directions indicated by arrows 450, 452 and/or 454 on rail
430 while drum 410 may move in the direction 455 and/or opposite to 455
as well as other directions. For example, in order to output, and thus
draw SAR 461, drum 410 may move in a direction 455 (or opposite to this
direction) while the nozzle 440 may remain in place. After a
circumferential line SAR 461 may be completed, the nozzle 440 may be
moved in direction 450 to draw SAR 462 while the drum 410 may remains
stationary. Likewise, the SAR 462 can be drawn by moving the drum 410 in
the direction of arrow 450 while the nozzle 440 remains stationary.
Furthermore, SAR 462 can be drawn by moving the drum 410 in one direction
along the path of arrow 450 and moving the nozzle 440 in an opposite
direction.

[0138] In an exemplary embodiment, the SARs 460-463 may be drawn in one
continuous deposit of flexible material by nozzle 440. Alternatively, the
SARs 460-463 may be drawn by depositing a plurality of layers, each layer
may comprise different flexible materials.

[0139] During the production of a single SARD 420 or SARCD, the drum 410
may rotate several times on its axis while the nozzle 440 may move a
single time on rail 430. In other embodiments, the drum 410 may rotate a
single time around its axis while nozzle 440 moves several times in
different directions. Optionally, the nozzle 440 may be moved along rail
430 at the same time as drum 410 rotates to draw a diagonal and/or curved
SAR. The speed and/or direction of rotation and/or movement of the nozzle
440 may depend on: the type and form of flexible material output, and the
section of the SAR 460-463 being drawn, the layout, etc. The speed and/or
direction of rotation and the movement of the nozzle 440 may be
controlled by controller 470, for example.

[0140] The flexible material deposited by the nozzle 440 may include one
or more different types of polymers or different combinations of two or
more polymers or material having similar characteristics. Exemplary
polymers that may be used are: polyester, polyamide, polycarbonate,
polyurethane, acrylic, polypropylene, polyethylene, etc. Furthermore, the
flexible-material may include one or more additives. The additives may
include, but are not limited to: silica, ceramics, metal, various fibers,
different fillers, etc.

[0141] In exemplary embodiments, the flexible material of the SARs may
comprise several layers (co-layers). Each layer may be made of different
materials and/or each layer may have a different: shape; cross-section;
width; comprise different polymer types and/or additives; etc. Each layer
may also have a different required set of attributes. More information on
layers of the SAR is presented herein in conjunction with the description
of FIG. 3d and FIGS. 9a-b.

[0142] The flexible material output by the nozzle 440 may be hardened
after and/or while the drawing is being performed. The hardening may be
accomplished by a hardener 480. The hardener 480 may irradiate energy
that can cause the drawn flexible material to harden and/or adhere.
Irradiated energy may include, but is not limited to: ultra violet (UV)
light, visible light, heat, etc. Alternatively, cooler air may be
directed at the drawn flexible material to cool and thus harden the
material.

[0143] The type of energy irradiated by the hardener 480 generally depends
on the type of flexible material and the hardening characteristics of
that material. For example, when the flexible material is a thermosetting
material, heat may be applied by the hardener 480. When the flexible
material is a thermoplastic material, the hardener 480 may cool the
material in order to harden it. Yet when the flexible material is
comprised of photo-initiator ingredients, the hardener 480 may illuminate
UV lighting in order to harden the flexible material. Optionally, when
one or more flexible materials utilized, one or more types of hardeners
480 may be used.

[0144] The hardener 480 may be positioned adjacent to the nozzle 440 such
that the flexible material may be hardened immediately after it is drawn.
In other exemplary embodiments the hardener 480 may be positioned at a
distance from the nozzle 440. In some embodiments, the hardener 480 may
not be provided in SART's rotary system 400 and SAR 460-463 may be
hardened by another system. In yet other exemplary embodiments, no
hardener 480 may be used.

[0145] In some exemplary embodiments, the hardener 480 may be used for
pre-treatment. The pre-treatments may include, but are not limited to:
ozone showers, primer coatings, surface roughening, etc. In embodiments
in which the hardener 480 is used for pre-treatment, the hardener 480 may
comprise different modules (not shown in drawings). Exemplary modules
include but are not limited to: laser beams, UV flash light, cartridge(s)
with primer substances, cartridge(s) with adhesive substances, and so on.
The hardener 480 and its modules may be controlled by the controller 470,
for example.

[0146] FIG. 5 illustrates an exemplary portion with relevant elements of a
surface-adhesive-rule technology's (SART) flat system 500. The SART's
flat system 500 may be used for drawing an exemplary SAR 560 on the
surface of a SARD's body 520 that may be positioned on a flat substrate
510. The SART's flat system 500 may include one or more rule-drawers.
Exemplary embodiments of the rule-drawer may comprise: a drawing-head
535, a controller 570, and one or more rails 530. The drawing-head 535
may comprise: at least one nozzle 540 and at least one cartridge 545
associated with or fluidly coupled to the nozzle 540.

[0147] The SAR 560 may be drawn by the at least one nozzle 540 associated
with the at least one cartridge 545. The nozzle 540 may further be
associated with a motor to cause the nozzle 540 to traverse along the
rail 530 in the directions of arrow 550, for example. Optionally, the
nozzle 540 may also be adapted to rotate in directions illustrated by
arrows 552 and/or 554. The rail 530 may be situated between two rails
535, substantially perpendicular to rail 530 and is adapted to travel in
the directions of arrow 555, for example.

[0148] Control 570 may be adapted to control the movement and coordinate
the different modules of the SART's flat system 500. For example the
controller 570 may control one or more of the nozzle 540, the rail 530,
the cartridge 545, etc. In some exemplary embodiments, the SART's flat
system 500 may further include a hardener 580 for hardening and/or
adhering the SAR 560 to the surface of the SARD's 520 body, similar to
hardener 480 shown and described in conjunction with the description of
FIG. 4. In some embodiments, flat substrate 510 may be adapted to move in
the directions depicted by arrow 555. It will be appreciated that various
other configurations may be used in various embodiments and as long as
the configurations allow the nozzle 540 and the body 520 of the SARD to
be moved relative to each other sufficiently to cover the required area
of the body 520 of the SARD, and to deterministically draw the SARs, then
the configuration is anticipated. In some embodiments, the SARD's body
520 may be bent around a cylindrical drum, after the deposition of the
SARs. The SART's flat system 500 and SART's rotary system 400 may be
similar in their functionality.

[0149] FIG. 6 depicts relevant elements of an exemplary embodiment of a
drawing-head 600. The drawing-head 600 may be comprised of a nozzle 640
for depositing flexible material. The nozzle 640 may be associated with
or fluidly coupled to a cartridge 645. The cartridge 645 may contain
flexible material and associated with a pressure actuator (not shown in
the drawing) for depositing the flexible material by injecting it or
forcing it through the nozzle 640 to draw a desired SAR. In some
embodiments, the nozzle 640 and its orifice may have various shapes. More
information on the different shapes and orifices is disclosed in
conjunction with the description of FIGS. 7a-b.

[0150]FIG. 7a is a schematic illustration of relevant elements of an
exemplary nozzle 700a. The exemplary embodiment of the nozzle 700a may
include a first tube 742 that may be substantially perpendicular to the
body 740 of the SARD. A second tube 744 may be oriented substantially
perpendicular to the first tube 742 and parallel to the body 740 of the
SARD. The tube 744 may have an orifice 746 at its end through which
flexible material may be output toward the body 740 of the SARD. The
orifice 746 may have different cross-sectional shapes. The
cross-sectional shapes of the orifice may be determined according to the
required SAR profile, for example. Exemplary cross-sectional shapes of
the orifice 746 may match the profile of the SARs depicted in FIG. 3a-f,
for example.

[0151]FIG. 7b is a schematic illustration of relevant elements of another
exemplary nozzle 700b. The exemplary embodiment of the nozzle 700b may
include a tube 752 that is oriented substantially perpendicular to a
SARD's body 750. The tube 752 may include an orifice 756 through which
flexible material may be output toward the body 750 of the SARD. The
orifice 756 may have various shapes as described in conjunction with
orifice 746 of FIG. 7a. Optionally, the tube 752 may be closed at its
distal end 758, and the material may be released substantially parallel
to SARD's body 750, through opening 756. Alternatively, distal end 758
may be open and the flexible material may be output in a substantially
perpendicular manner through distal end 758 as well as through 756, and
so on. Wherein substantially perpendicular may be in the range of 90
degree plus/minus 30 degrees, for example.

[0152] Other nozzles may be used in accordance with embodiments of the
present disclosure. For example, nozzles manufactured by Nordson
Corporation which can be viewed at the following URL
www<dot>nordson<dot>com may be utilized. The types of nozzles
used may differ according to: the material that is being output onto the
SARD, the required shape of SAR, etc. In some exemplary embodiments, the
orifice of the nozzle may be directed in a direction opposite to the
relative direction of motion of the nozzle with respect to the surface of
the SARD's body 750. In exemplary embodiments the orifice of the nozzle
may be parallel to the surface of the SARD's body 750. In alternate
embodiments the nozzle may be at a pre-defined angle to the surface of
the SARD's 750. Exemplary angles may be at the range of 45-135 degree.

[0153] FIG. 8a schematically illustrates a simplified diagram with
relevant elements of an exemplary pressure actuator 800a. The pressure
actuator 800a may be an air-pump actuator, for example. A cartridge 810
may contain a flexible material 814, for example. The flexible material
814 may be used to draw SARs for example. The cartridge 810 may have an
output 816 through which the flexible material 814 may be output or used
to fluidly couple the cartridge 810 to a nozzle. The cartridge may have
an input 812 through which air may be compressed and thus press the
material out of the cartridge's output 816 via a nozzle (not shown in
drawing) according to a SAR layout. The air may be compressed by a piston
808, for example. The piston 808 may be controlled by a controller
similar to the controller 470 of SART rotary system 400 and/or controller
570 of SART flat system 500. Pressure actuators 800a may have suction
capabilities as well.

[0154] FIG. 8b schematically illustrates a simplified diagram with
relevant elements of exemplary pressure actuators 800b. The pressure
actuator 800b may an electrical cogwheel pump, for example. The cartridge
810 and flexible material 814, may be similar to that as described for
the cartridge 810 and flexible material 814 in FIG. 8a. The flexible
material 814 may be carried by a cogwheel 822 out of the cartridge output
816. The cogwheel 822 may be actuated by an electric/step motor 818, for
example. The operation of the cogwheel 822 and the motor 818 may be
controlled by a controller similar to controller 470 of SART rotary
system 400 and/or controller 570 of SART flat system 500. The flexible
material may be output from the cogwheel's 822 output 820 to a nozzle
(not shown in the drawing) according to a SAR layout. Pressure actuator
800b may have suction capabilities as well.

[0155] FIG. 8c schematically illustrates a simplified diagram with
relevant elements of an exemplary pressure actuator 800c. The pressure
actuator 800c may be a screw-piston pump, for example. The screw-piston
pump may be comprised of a screw 822 associated with a plate 824, and an
engine or motor 823, for example. Cartridge 810 and flexible material
814, may be similar to the cartridge 810 and flexible material 814
described in FIG. 8a. The flexible material 814 may be pressed out of the
cartridge output 816 by the screw-piston pump as the screw 822 is screwed
by the engine 823, thus causing the plate 824 to press the flexible
material 814 out of the cartridge 810 output towards a nozzle (not shown
in drawing) according to a SAR layout. The operation of the screw-piston
pump 800c may be controlled by a controller similar to controller 470 of
SART rotary system 400 and/or controller 570 of SART flat system 500. The
screw-piston pump 800c may have suction capabilities as well.

[0156] FIG. 8d schematically illustrates a simplified diagram with
relevant elements of an exemplary pressure actuator 800d. The pressure
actuator 800d may be a screw pump 832, for example. The cartridge 810 and
flexible material 814, may be similar to the cartridge 810 and flexible
material 814 described for FIG. 8a. The flexible material 814 may be
carried out between the spindles of the screw 832 toward the cartridge
output 816 and towards a nozzle (not shown in drawing) according to a SAR
layout by the screw pump 832 as the screw pump 832 is screwed by an
engine 833. The operation of the screw pump 832 may be controlled by a
controller similar to controller 470 of SART rotary system 400 and/or
controller 570 of SART flat system 500. The screw pump 832 may have
suction capabilities as well.

[0157] FIG. 8e schematically illustrates a simplified diagram with
relevant elements of an exemplary pressure actuator 800e. The pressure
actuator 800e may be a screw pump 832, for example. The pressure actuator
800e may be similar to the pressure actuator 800d described in
conjunction with FIG. 8d. The pressure actuator 800e may further comprise
a cut-off mechanism. The cut-off mechanism may comprise a tube 842 in
which pulses of air, liquid, etc. may pass through in the direction of
arrow 844, for example. The air, liquid, etc. pulses may be created by a
pulse-pump 843 associated with the tube 842, for example.

[0158] The cut-off mechanism may further comprise a switch/valve that may
be controlled by a controller similar to controller 470 of SART rotary
system 400 and/or controller 570 of SART flat system 500. The pulse-pump
843 may be controlled by the controller, as well. The switch/valve may
comprise a shutter arm 846 or may be a ball valve or other structure. The
switch/valve may have two modes. One mode may be an open-mode in which
the shutter arm 846 is substantially parallel to tube 842. The second
mode may be a closed-mode in which the shutter arm 846 is substantially
perpendicular to tube 842 or oriented in a manner to prevent flow.

[0159] In an exemplary embodiment, when the cut-off mechanism is
activated, at the end of a SAR drawing for example, the following actions
may take place: output of the flexible material by screw-pump 832 is
stopped; the screw-pump 832 may be screwed in the counter-clockwise
direction (or retracted); the shutter arm 846 is switched to open-mode in
the direction similar to arrow 848; a pulse of air, liquid, etc. may be
created and output from the pulse-pump 843 in direction of arrow 844. In
other exemplary embodiments one or more shutter arms or valves may be
used.

[0160] FIG. 8f schematically illustrates a simplified diagram with
relevant elements of an exemplary pressure actuator 800f. The pressure
actuator 800f may be similar to pressure actuators 800a-e described in
conjunction with FIGS. 800a-e. The pressure actuators 800f may further
comprise a filling mechanism. The filling mechanism may comprise a
reservoir 856 that may contain flexible-material 814; a tube 858 in which
the flexible material may pass through; and a switch/valve that may be
controlled by a controller similar to controller 470 of SART rotary
system 400 and/or controller 570 of SART flat system 500.

[0161] The switch/valve may comprise a shutter arm 854. The switch may
have two modes. One mode may be open-mode in which the shutter arm 854 is
substantially parallel to tube 858 and may shut aperture 860. The second
mode may be closed-mode in which the shutter arm 854 is substantially
perpendicular to tube 858 or oriented such that the flow from tube 858 is
restricted.

[0162] In an exemplary embodiment, when the filling mechanism is
activated, and the cartridge 810 is required to be filled with flexible
material 814 for example, the following actions may take place: output of
the flexible material from output 816 is stopped; piston 808 may be
pulled outward from cartridge 810; the shutter arm 854 may be switched to
open-mode in the direction similar to arrow 852; flexible material may be
output from the cartridge 856 toward the shutter arm 846. In other
exemplary embodiments one or more shutter arms may be used. In other
embodiments the cartridge 810 may be filled through opening 812, for
example. The cartridge 856 may be easily and quickly disconnected from
tube 858, and replaced with another one, for example. The Cartridge 856
and it's flexible material may be purchased by the owner of the SART
system.

[0163] FIG. 9a depicts a simplified diagram with relevant elements of an
exemplary embodiment of a multiple-compartment cartridge 900. The
multiple-compartment cartridge 900 may be used to draw a co-layer SAR,
for example. The multiple-compartments cartridge 900 may comprise a
plurality of compartments 902, 904, and 906 for example. Each compartment
may comprise a cartridge and a pressure actuator (not shown in the
drawings), for example. Each compartment 902, 904, and 906 may contain,
separately, one or more ingredients of flexible material. In alternate
embodiments each compartment may comprise a different flexible material,
for a different layer of the co-layer, and so on.

[0164] The cartridge 900 may further comprise a combiner 908. In exemplary
embodiments, the combiner 908 may combine the different ingredients
and/or flexible material, for example. The combiner 908 may comprise a
slot/aperture 910 through which the combined material from the different
compartment 902, 904, and 906 may be output. A controller, 470 (FIG. 4)
and/or controller 570 (FIG. 5), may control the quantities of each
ingredient/material/layer. In some exemplary embodiment one or more of
the different compartments 902, 904, and 906 may comprise adhesive
substance. In addition, the combiner 908 may include an agitator (not
shown) to facilitate the mixing and combining of the materials from two
or more of the different compartments 902, 904, and 906.

[0165] The different layers may be bonded to one another during different
hardening techniques, for example. Exemplary hardening techniques
include, but are not limited to: temperature treatment, Ultra-Violet (UV)
curing, visible light, infra red light, chemical curing, cooling etc. In
other embodiments, the different layers may be bonded by an adhesive. In
such embodiments, an adhesive substrate layer compartment may be placed
between the compartments comprising the layers that will need to be
adhered. In yet other embodiments the bonding may be a combination of the
above techniques.

[0166] FIG. 9b schematically illustrates a co-layer creation by an
exemplary embodiment of a multiple-compartment cartridge 910. The
multiple-compartment cartridge 910 may comprise a plurality of
compartments 912, 914, and 916 for example. The compartment 916 may be
the leading edge of the drawing head 910. Each compartment may comprise a
cartridge and a pressure actuator (not shown in the drawing). In an
exemplary embodiment, each compartment may comprise a different flexible
material, for a different layer of the co-layer, and so on. A controller,
470 (FIG. 4) and/or controller 570 (FIG. 5), may control the co-layer
drawing, for example. In some exemplary embodiments, one or more of the
different compartments 912, 914, and 916 may comprise adhesive substance.
The multiple-compartments cartridge 910 may have a stair-like shape edge.

[0167] In some embodiments, the co-layer may be created in phases. An
exemplary phase technique includes, but is not limited to: drawing a
first layer on the surface, next drawing on top of it the next layer and
so on. This exemplary embodiment may comprise a plurality of cartridges.
Each cartridge may comprise a different material for a different layer
and/or adhesive substance. The controller may control the operation. In
some embodiments, a combination of the different co-layer techniques and
multiple-compartments cartridge may be used.

[0168] FIG. 10a-d schematically illustrates a flowchart showing relevant
processes or actions of an exemplary rule drawing method 1000. The
illustrated rule drawing method 1000 may be executed by a controller, a
microprocessor, a microcontroller, a computer or any other processing
device including (collectively referred to as a controller), but not
limited to controllers similar to controller 470 (FIG. 4) and/or
controller 570 (FIG. 5). The method 1000 may be initiated 1002 upon
powering on the controller but, it will be appreciated that the method
1000 may be initiated or invoked from other processes, system, events,
user actions, etc. During initiation 1002, the controller may operate to
detect the various modules in the system or, the various modules or other
processors may provide information to the controller to identify the
different modules. Exemplary modules may include, but are not limited to:
drawing head modules, different registers, different timers, etc. After
being invoked the process may then act to reset, initialize or determine
the state of various resources, registers, variables, memory components,
etc. 1004. The various resources may include, but are not limited to:
timers (t), counters (R), distance measurers (D), and so on.

[0169] After the system resources have been initialized 1004, the rule
drawing method 1000 may enter into a delay loop waiting for the reception
of an initiation command 1006. The initiation command directs the rule
drawing method 1000 to commence the creation of a SARD. When an
initiation request is received 1006, the method 1000 may proceed to act
1008 by receiving or obtaining the entry of various inputs or parameters
used in the creation of SARD. The inputs may be received, obtained or
entered by a user, provided by a processor or other entity, read from an
electronic file, etc. Exemplary inputs may include, but are not limited
to: the depth or thickness of the cardboard that will be pre-treated
while using the SARD, the type of surface-adhesive rules (SAR) that will
be required, the requested layout, and so on. The method 1000 may check
1010 a look-up table for information on the required job description.
Exemplary information may include, but is not limited to: the definition
of flow index for each SAR, the definition of profile for each SAR, the
definition of the layers for the co-layers, the type of SAR
(cutting/embossing/creasing), etc.

[0170] Once the information has been received, the method then decides
whether additional information in the look-up table has been found or is
available 1012. If additional information is not found 1012, then method
1000 may prompt the user or other information provider to enter or
provide the information 1014, and processing then returns to act 1008 to
check for this information. If the method obtains the information in the
look-up table or otherwise 1012, then the method 1000 may proceed to act
1018. The method 1000 may then proceed to execute a SAR drawing loop that
comprises the acts listed in blocks 1018 through 1046 (FIG. 10d). The
first action in the SAR drawing loop comprises increasing counter R by
one (incrementing R) 1018, and the method 1000 may begin drawing a SAR in
accordance with the information received at action 1010 and layout
requirements, for example.

[0171] Once the counter is increased, the method continues by adjusting or
setting the height and angle of a nozzle t 1020. In addition, the
velocity of the drawing head modules may be accelerated 1020 to a
required velocity V1 by acceleration rate a1, for example. The pressure
applied by a one or more pressure actuators may also be raised 1020 to a
required pressure P1, and so on. Yet, in alternate embodiments, in which
screw-pumps are used for example, instead of raising pressure P1, a
screwing speed is raised. Next the method 1000 may proceed to act 1022 at
FIG. 10b.

[0172] After adjusting or setting the nozzle, velocity and pressure, the
method continues by entering a delay loop 1022 until the value of timer t
is equal to t1. The value of t1 may be calculated according to the
mechanical capabilities of the drawing-head and the length required for
the SAR or SAR segment according to the layout. When timer t value is
equal to the value of t1, the acceleration rate a1 of the velocity of the
drawing head modules may be stopped 1024 and the raising of the pressure
of the pressure actuator may be stopped 1024 as well. Thus the drawing
head modules may continue drawing at velocity V1 and the pressure
actuator may continue pressing at pressure P1. In alternate embodiment
instead using a timer, a distant measurement D may be used. The distant
measurement D may be expressed by a number of steps given to a step-motor
or by feedback received from a step measurement encoder associated to the
drawing head.

[0173] While the drawing continues, the method 1000 may enter into a delay
loop until the value of counter t is equal to t2 1026. Wherein t2 may be
calculated from inputs on the drawn pattern of the SAR and the velocity
that was reached at t1. When the timer t value is equal to t2 1026, the
velocity of the drawing head modules may be decelerated 1028 to V2 at
deceleration rate a2, and the pressure by the pressure actuator may be
decreased 1028 to P2. In exemplary embodiments, the nozzle may be 1030
elevated X mm and turned 1030 to an angle O according to the requirements
of the layout. Next the nozzle may be lowered 1030 Z mm (wherein Z may
equal X).

[0174] The method 1000 continues by accelerating the drawing head modules
to a velocity of V1 at an acceleration rate of a1, and the pressure of
the pressure actuator may be raised to P1 1032. The drawing head modules
may continue to draw 1032 the SARs according to the layout. The method
1000 may then proceed to act 1034 at FIG. 10c.

[0175] The method 1000 continues at act 1034 of FIG. 10c by entering a
delay loop until the value of the timer t is equal to t3 1034. When the
timer t value is equal to t3 1034, the acceleration of the velocity of
the drawing head modules and the raising of the pressure by the pressure
actuator may be stopped 1036. The drawing head modules may continue
drawing at velocity V1 and the pressure actuator may continue at pressure
P1 1036. Next, the method 1000 may enter a delay loop until the value of
timer t is equal to t4 1038. When the timer t value is equal to t4 1038,
the pressure imposed by the pressure actuator may be stopped 1040, and
the motion of the drawing head modules may be stopped 1040 as well. The
nozzle may be elevated to a desired level by raising it Y mm and spun
sharply 1042 at a certain degrees (180-360 degrees for example) degree
around its center, for example. The spinning of the nozzle operates to
cut the flexible material from the nozzle. In an alternate embodiment, an
air-pulse may be used in order to cut the flexible material from the
nozzle as disclosed above in conjunction with the description of FIG. 8e,
for example. Yet in other embodiments, a shutter may be used as disclosed
in FIGS. 8e-8f. In even other exemplary embodiments, a guillotine may be
utilized to cut the flexible material from the nozzle, or an air knife
may be used to cut the flexible material from the nozzle at once, and so
on. The method 1000 may then proceed to act 1044 at FIG. 10d.

[0176] At this point in the process, the method 1000 may provide a notice
or indicator 1044, such as by turning on a light, making a sound or
placing text or icons on a display as non-limiting examples, that the
Surface-adhesive rule (SAR) has been drawn. Next, the method 1000
determines whether all of the SARs have been drawn and the job has been
finished 1046. If the job is finished 1046, then the method 1000 may
provide a notice or indicator 1048, such as by turning on a light, making
a sound or placing text or icons on a display for example, that the job
as been finished and method 1000 may end. If the job has not yet been
finished and more SARs need to be drawn 1046, then method 1000 may return
to act 1018 at FIG. 10a to start drawing the next SAR.

[0177]FIG. 11 depicts a simplified diagram with relevant elements of yet
another exemplary surface-adhesive-rule technology (SART) system 1100. In
an exemplary SART system 1100, the deposited flexible material may be in
the form of a flexible strip 1110. The flexible strip 1110 may be
positioned in a cartridge 1118. The flexible strip 1110 may be rolled as
shown in FIG. 11 or may be folded in other ways, such as a fan
configuration. The cartridge 1118 may be associated with a rail 1114. The
rail 1114 may be similar to the rail 430 described in FIG. 4a, for
example. In some embodiments, the cartridge 1118 may be associated with a
nozzle 1112. The flexible strip 1110 may be bent and/or curved during
deposition in order to draw the desired pattern of SAR.

[0178] In some exemplary embodiments, the flexible strip 1110 may be cut
by a knife 1116 when the SAR drawing reaches the end of the SAR. In
alternate embodiments, other terminator-systems and techniques may be
used. The deposited flexible strip 1110 may be bonded to the surface of
the SARD's body (not shown in drawing) by adhesion for example.

[0179] FIG. 12a depicts a schematic illustration of relevant elements of
yet another exemplary embodiment of a surface-adhesive-rule technology
(SART) system 1200 depositing pieces of material 1212. Exemplary material
1212 may be pieces of magnetic material that are to be deposited onto a
SARD's body 1220. The SART system 1200 may include a magazine 1210 in
which small pieces of magnetic material 1212 are positioned. A shear 1222
may be adapted to move in directions along arrow 1226 and push single
pieces 1218 out of the magazine 1210 to the opening of a channel 1219. In
an exemplary embodiment, an applicator 1216 may push the piece of
material 1218 through the channel 1219 toward a SARD's body 1220 by a
motor 1214. The SARD's body 1220 and/or SART system 1200 may move so that
a SAR 1224 is drawn by depositing the material 1218 onto the SARD's body
1220 in a required place.

[0180]FIG. 13 depicts a schematic illustration of relevant elements of an
exemplary SARD 1300 that may be produced by SART system 1200 illustrated
in FIG. 12 above. The SAR die 1300 may be comprised of a SARD body 1310
and one or more SARs 1320 that are bonded to the surface of the SARD body
1310. The SARD body 1310 may be made of iron or other magnetic or pseudo
magnetic material. As such, the bonding may wholly provided by magnetic
forces, for example, or additional adhesive or bonding techniques may be
used to further strength the bond. Each SAR 1320 may be made of a
plurality of magnetic pieces 1330. The magnetic pieces 1330 may be
deposited adjacent to each other in accordance with the layout of the
required SARD, thus creating a continuous SAR 1320.

[0181] In an exemplary embodiment, the pieces of material 1330 may have a
size of approximately 1 mm cube, such as for example between 500-700
microns cube. However, it will be appreciated that the pieces of material
can also be in other sizes as well as shapes, such as rectangular cubes,
trapezoids, elongated, etc. In an exemplary embodiment, a peel strength
between the pieces of material 1330 and the SARD's body 1310 may be about
13 gr/mm2. In some exemplary embodiments, an adhesive is provided
between the magnetic pieces 1330 and the SARD's body 1320. Optionally, an
adhesive is provided on the bottom surface of the magnetic material 1330
facing the SARD's body 1320. Alternatively or additionally, adhesive is
provided on the SARD's body 1320. Further, the adhesive may be deposited
on the SARD's body 1320 by a nozzle (not shown in the drawing).

[0182]FIG. 14a illustrates a schematic portion with relevant elements of
a SARD 1400a in accordance with yet another exemplary embodiment of the
present disclosure. The entire surface or portions of the surface of the
surface of the SARD's body 1410 may be coated with a low surface tension
material 1420. Pre-defined areas, according to the layout, of the surface
of the SARD's body 1410 may then be coated with a high surface tension
material 1415. In some embodiments, the low surface tension material 1420
can be laid on the entire surface or portions of the surface of the
SARD's body 1410 and then the high surface tension material 1415 can be
laid over the low surface tension material 1420 or, the low surface
tension material 1420 and the high surface tension material 1415 can be
applied onto mutually exclusive surface areas of the SARD's body 1410.

[0183] A liquid or gel like material 1430 may be deposited on the surface
of the SARD's body 1410, as shown in FIG. 14b. The liquid or gel like
material 1430 may then coalesce from the low surface tension areas to the
high surface tension areas, thereby creating one or more SARs 1440 at the
desired locations, as shown in FIG. 14c.

[0184] In alternate exemplary embodiments, the liquid or gel like material
1430 may be deposited only on areas surrounding the high surface tension
areas. Alternatively, liquid or gel like material 1430 may be deposited
on the entire body 1410 or most of surface of the SARD's body 1410.
Optionally, the liquid or gel like material 1430 may be flexible material
based on polymer.

[0185] The deposited liquid or gel like material 1430 will generally move
to the high surface tension area after a certain period of time (between
a few minutes and 2-3 hours, for example). In exemplary embodiments the
liquid or gel like material 1430 may be left at room temperature of about
25-30° C. Alternatively, the temperature of the deposited liquid
or gel like material 1430 may be raised by about 10° C. which may
reduce the time of coalescing of the liquid or gel like material 1430. In
addition, agitators or vibrators may be used to vibrate the SARD and
thereby assist in accelerating the coalescing of the material 1430.

[0186] In other exemplary embodiments the liquid or gel like material 1430
may be hardened only after a period of time after deposition. The height
of the created SARs 1440 may be a few millimeters, such as 700
microns-1.25 mm for example. The width of the created SARs 1440 may be a
few millimeters, such as 700 microns-1.25 mm for example.

[0187] In some exemplary embodiments of the present disclosure the surface
of the SARD's body 1410 may be formed of or coated with a high surface
tension material and then coated or primed over this layer with a low
surface tension material. A desired layout of the SARs may be engraved in
the low surface tension coating, such that the desired layout will expose
the high surface tension material present beneath the low surface tension
coating while the rest of SARD's body 1420 will be coated with a low
surface tension material. Exemplary high surface tension materials may
include, but are not limited to, PET, Corona treated PP, Polyamide and
Aluminum laminate. Exemplary low surface tension materials are silicon,
TFE or Polyethylene.

[0188]FIG. 15 depicts a schematic illustration of relevant elements of
yet another exemplary surface-adhesive-rule technology (SART) system
1500. The SART system 1500 may include an engraving mechanism 1530, a
rail 1550 and a nozzle 1540. The engraving mechanism 1530 may be any
suitable device that can provide adequate engraving, such as but not
limited to, a laser and/or a mechanical tool for example. The rail 1550
is suitable for both the nozzle 1540 and the engraving mechanism 1530 to
be positioned on the surface of the rail 1540. Alternatively, the
engravings may be performed in a system other then the SAR drawing
system. In an exemplary operation of the illustrated SART system 1500,
the engraving mechanism 1530 may be used to etch an area of the SARD 1520
to receive a SAR pattern and then the nozzle 1540 can apply material for
the SAR within the etched areas.

[0189] In alternate embodiment the module 1530 may be a scrapper which may
be used to milled/scrap the edge of a drawn cutting SAR. In yet another
alternate embodiment the module 1530 may be a hardening module, such as
but not limited to a light source, a air knife, etc.

[0190] FIG. 16a depicts relevant elements of a portion of an exemplary
embodiment of a molding system 1600. Molding system 1600 may be used in
the creation a SAR counter die body and/or a SAR die body. Molding system
1600 may comprise an open top mold 1602, into which gel/liquid like
material 1604 may be input. The gel/liquid like 1604 material may
comprise one or more different polymers. Exemplary polymer may be:
polyurethane, monothane with shore hardness of around A30-A70 of DOW
company, etc. Further the gel/liquid like material may comprise one or
more different additives. Exemplary additives may be accelerators such
as, but not limited to: Dibutyltin dilaurate. Other exemplary additives
may be: silica, ceramics, metal, various fibers, different fillers. The
open top mold 1602 may be coated with release coating (not shown in
drawing). Exemplary release coating may be Cilrelease 905 of DOW Company.

[0191] In some embodiments a flexible film 1606 may be added to be
associated to the gel/liquid like material 1604. The flexible film 1606
may be made of different materials. Exemplary materials may be: PET
(Polyethylene terephthalate), PA (Polyamide), polypropilen, stainless
steel, Aluminum (Al) and/or a combination of them, etc. In some
embodiments the flexible film 1606 may be added on top of the gel/liquid
like material 1604, while in other embodiments it may be added at the
bottom of the gel/liquid like material 1604. Furthermore the flexible
film 1606 length may exceed the open mold length, in these cases the open
top mold 1602 may have fitted apertures (not shown in drawings).

[0192] The mold with the gel/liquid like material 1604 and the flexible
film 1606 may pass a hardening process. Exemplary hardening may be curing
by heat, curing by light (UV, infra red, visible light, etc), curing by
cooling, and so on. The temperature and time of the hardening may be
according to the gel/liquid like material's 1604 composition of
ingredients and/or its dimensions. For example, hardening of polyurethane
may be around 135 degrees Celsius for 6 hours. In alternate embodiment
the hardening of polyurethane may be around 135 degrees Celsius for a few
minutes if added to it are additives with high sensitivity to heat, and
so on.

[0193] In some exemplary embodiments after the hardening process, the
flexible film 1606 may be pierced 1608. The piercing may be done by
different techniques. Exemplary techniques may be: by a puncher, a laser,
etc.

[0194] FIG. 16b depicts relevant elements of a portion of an exemplary
embodiment of a closed molding system 1620. Closed molding system 1620
may be used in the creation a SAR counter die body and/or a SAR die body.
Closed molding system 1620 may comprise a closed mold 1622, into which
gel/liquid like material 1614 may be input with or without a flexible
film 1606, similar to the one disclosed in FIG. 16a. Closed molding
system 1620 may further comprise a lid 1626, and one or more excess
release channels 1628. The gel/liquid like material 1614 may be injected
into the mold 1612 by extruder points in the mold 1612 (not shown in the
drawing.) or placed with or without a flexible film 1606 inside the mold
1622 when the lid 1626 is open and only then the lid may be placed closed
1626.

[0195] The mold with the gel/liquid like material 1614 with or without a
flexible film 1606 may pass hardening process. Exemplary hardening may be
curing by heat, curing by light (UV, infra red, visible light, etc),
curing by cooling, etc. The conditions and times of the hardening
techniques may be similar to the ones disclosed in conjunction with FIG.
16a. The mold 1622 may be coated with release coating (not shown in
drawing). Exemplary release coating may be Cilrelease 905 of DOW Company.
In some exemplary embodiments after the hardening process, the flexible
film 1606 may be pierced 1630. The piercing may be done by different
techniques. Exemplary techniques may be: by a puncher, a laser, etc.

[0196] FIG. 17a depicts relevant elements of a portion of an exemplary
embodiment of a press system 1700. Press system 1700 may be used in the
creation a SAR counter die body and/or a SAR die body. Press system 1700
may comprise a base 1708, a mold 1702, and a top 1706. Top 1076 may be
part of a pressure actuator (a piston pressure actuator, for example). A
plurality of materials 1704 may be input into the mold 1702. Materials
1704 such as, but not limited to: different polymers, additives, etc.
Exemplary polymers may be: polyurethane, EPDM (ethylene propylene diene
Monomer rubber), silicon, acrylic, etc. Different additives may be:
Graphite, Dibutyltin dilaurate, silica, ceramics, metal, various fibers,
and/or different fillers.

[0197] The press process may comprise one or more phases. For example a
first phase may comprise flatting the materials 1704 as depicted in FIG.
17b material 1710. This phase may comprise heating the materials 1704 and
exerting pressure on them by the top 1706, for example. The second phase
may comprise exerting higher pressure and heat and hardening the
material. Hardening may be done by curing via light (UV, Infra red,
visible light, etc), or by heating, or by cooling.

[0198] Exemplary conditions for the second phase for different materials
is disclosed in table 11 below:

[0199]FIG. 17c depicts relevant elements of a portion of an exemplary
embodiment of an injection/extruder molding system 1720.
Injection/extruder molding system 1720 may be used in the creation a SAR
counter die body and/or a SAR die body. Injection/extruder molding system
1720 may comprise: a closed mold 1712, one or more injecting apertures
1722, one or more excess release channels 1718. Liquid/gel like material
may be heated and injected 1720 with pressure to the closed mold 1712 via
the one or more injecting apertures 1722. The Liquid/gel like material
may be different polymers, additives, etc. Exemplary polymers may be:
polyurethane, EPDM (ethylene propylene diene Monomer rubber), silicon,
acrylic, etc. Different additives may be: Graphite, Dibutyltin dilaurate,
silica, ceramics, metal, various fibers, different fillers, etc. The mold
1712 may be coated with release coating (not shown in drawing). Exemplary
release coating may be Cilrelease 905 of DOW Company. Next a hardening
process may be implemented. Hardening may be done by curing via light
(UV, Infra red, visible light, etc), or by heating, or by cooling.
Exemplary conditions for the hardening for different materials are
disclosed in table 11 above.

[0200]FIG. 18 depicts relevant elements of a portion of an exemplary
embodiment of a coating system 1800. Coating system 1800 may be used in
the creation a SAR counter die body and/or a SAR die's body. Exemplary
liquid/gel-like material that may be used in the coating system 1800 may
be different polymers with different additives. Exemplary polymers may be
silicon, acrylic, etc. Exemplary additives can be: Graphite, Dibutyltin
dilaurate, silica, ceramics, metal, various fibers, and/or different
fillers. In some embodiments the liquid/gel-like material may be solvent
base. Exemplary solvent may be: MEK (Methyl Ethyl Ketone), Toluene, etc.

[0201] Coating system 1800 may comprise: an un-winder 1802, a coating head
1806, a chamber 1808, and a winder 1812. Chamber 1808 may comprise an
oven, a light radiator, and or a cooling mechanism, for example. On the
un-winder 1802 a film 1810 may be winded. The film may be a PET
(Polyethylene terephthalate), PA (Polyamide), polypropilen, stainless
steel, Aluminum (Al) and/or a combination of them, etc. Winder 1812 may
pull and wind the film on the other end of the coating system 1800. The
film may then pass the coating head 1806. The coating head 1806 may coat
the film with a layer of the liquid/gel-like material 1811. Next the
coated film may pass through a chamber 1808 for hardening. In some
embodiments there may not be a need for the chamber 1808. The coated and
hardened film may pass through a surface treatment (not shown in the
drawing). Exemplary surface treatment may be polish, grinding, scarping,
etc. The coated and hardened film may then be winded on the winder 1812,
for example.

[0202] In some exemplary embodiments there may be one or more coating
heads 1806 one or more chambers 1808. In other exemplary embodiments the
coated film may pass in a loop through the coating heads 1806 one or more
chambers 1808. The one or more coating heads 1806 may comprise different
liquid/gel-like material 1811.

[0203] In exemplary embodiments the creation a SAR counter die's body
and/or a SAR die's body may be implemented in one or more different
methods (molding, press, coating, etc) and/or a combination of them. In
some of the molding techniques a negative pattern may be used inside the
mold in order to create a required pattern and/or layout for the SAR
counter die's body and/or a SAR die's body.

[0204] Other exemplary embodiments may use a thermoplastic material for
the creation a SAR counter die's body. In such embodiments an additional
phase may be added in the creation. The additional phase may comprise
imprinting the SARs on the thermoplastic material at a required
temperature. Exemplary temperature may be around 69 C. degree for
example.

[0205]FIG. 19 is a functional block diagram of the components of an
exemplary embodiment of system or sub-system operating as a controller or
processor 1900 that could be used in various embodiments of the
disclosure for controlling aspects of the various embodiments. It will be
appreciated that not all of the components illustrated in FIG. 19 are
required in all embodiments of the activity monitor but, each of the
components are presented and described in conjunction with FIG. 19 to
provide a complete and overall understanding of the components. The
controller can include a general computing platform 1900 illustrated as
including a processor/memory device 1902/1904 that may be integrated with
each other or, communicatively connected over a bus or similar interface
1906. The processor 1902 can be a variety of processor types including
microprocessors, micro-controllers, programmable arrays, custom IC's etc.
and may also include single or multiple processors with or without
accelerators or the like. The memory element of 1904 may include a
variety of structures, including but not limited to RAM, ROM, magnetic
media, optical media, bubble memory, FLASH memory, EPROM, EEPROM, etc.
The processor 1902, or other components in the controller may also
provide components such as a real-time clock, analog to digital
convertors, digital to analog convertors, etc. The processor 1902 also
interfaces to a variety of elements including a control interface 1912, a
display adapter 1908, an audio adapter 1910, and network/device interface
1914. The control interface 1912 provides an interface to external
controls, such as sensors, actuators, drawing heads, nozzles, cartridges,
pressure actuators, leading mechanism, drums, step motors, a keyboard, a
mouse, a pin pad, an audio activated device, as well as a variety of the
many other available input and output devices or, another computer or
processing device or the like. The display adapter 1908 can be used to
drive a variety of alert elements 1916, such as display devices including
an LED display, LCD display, one or more LEDs or other display devices.
The audio adapter 1910 interfaces to and drives another alert element
1918, such as a speaker or speaker system, buzzer, bell, etc. The
network/interface 1914 may interface to a network 1920 which may be any
type of network including, but not limited to the Internet, a global
network, a wide area network, a local area network, a wired network, a
wireless network or any other network type including hybrids. Through the
network 1920, or even directly, the controller 1900 can interface to
other devices or computing platforms such as one or more servers 1922
and/or third party systems 1924. A battery or power source provides power
for the controller 1900.

[0206] In the description and claims of the present disclosure, each of
the verbs, "comprise", "include" and "have", and conjugates thereof, are
used to indicate that the object or objects of the verb are not
necessarily a complete listing of members, components, elements, or parts
of the subject or subjects of the verb and further, all of the listed
objects are not necessarily required in all embodiments.

[0207] As used herein, the singular form "a", "an" and "the" include
plural references unless the context clearly dictates otherwise. For
example, the term "a material" or "at least one material" may include a
plurality of materials, including mixtures thereof.

[0208] In this disclosure the words "unit", "element", and/or "module" are
used interchangeably. Anything designated as a unit, element, and/or
module may be a stand-alone unit or a specialized module. A unit,
element, and/or module may be modular or have modular aspects allowing it
to be easily removed and replaced with another similar unit, element,
and/or module. Each unit, element, and/or module may be any one of, or
any combination of, software, hardware, and/or firmware. Software of a
logical module can be embodied on a computer readable medium such as a
read/write hard disc, CDROM, Flash memory, ROM, etc. In order to execute
a certain task a software program can be loaded to an appropriate
processor as needed.

[0209] The present disclosure has been described using detailed
descriptions of embodiments thereof that are provided by way of example
and are not intended to limit the scope of the disclosure. The described
embodiments comprise different features, not all of which are required in
all embodiments of the disclosure. Some embodiments of the present
disclosure utilize only some of the features or possible combinations of
the features. Many other ramifications and variations are possible within
the teaching of the embodiments comprising different combinations of
features noted in the described embodiments.

[0210] It is appreciated that certain features of the invention, which
are, for clarity, described in the context of separate embodiments, may
also be provided in combination in a single embodiment. Conversely,
various features of the invention, which are, for brevity, described in
the context of a single embodiment, may also be provided separately or in
any suitable sub-combination or as suitable in any other described
embodiment of the invention.

[0211] It will be appreciated by persons skilled in the art that the
present disclosure is not limited by what has been particularly shown and
described herein above. Rather the scope of the disclosure is defined by
the claims that follow.

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